Universal Battery Pack Endplate with Multi-Position Connectors
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Solution Overview
Problem
The complexity in designing endplates for battery arrays increases due to varying orientations of battery cells within electrified vehicles, requiring unique designs for different orientations which complicates manufacturing and increases costs.
Innovation Solution
A versatile endplate design with interchangeable connectors and lifting features that can secure to both a support tray and a heat exchanger plate, allowing it to accommodate both side-oriented and standard-oriented battery cells, reducing the need for multiple unique designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If unique endplate designs are created for each battery cell orientation, then the endplate can be optimized for specific orientations, but design complexity and manufacturing costs increase
Solution Approach 1:
The endplate is designed with multiple connectors positioned at different locations (first connector in first side region, second connector in second side region, third connector in third side region) allowing a single endplate design to accommodate battery cells in multiple orientations (side-oriented and standard-oriented) and secure to different components (support tray, heat exchanger plate). This universal design eliminates the need for separate endplate variants for different orientations.
2Reliability
If unique endplate designs are created for each battery cell orientation, then securement is optimized for each orientation, but manufacturing costs and tooling requirements increase
Solution Approach 1:
A single endplate design with multiple connectors provides reliable securement for different battery orientations and configurations, eliminating the need for multiple unique designs and reducing manufacturing complexity and tooling requirements.
Solution Approach 2:
The endplate is divided into distinct side regions (first side region, second side region, third side region) with connectors positioned in each region. This segmentation allows the same endplate to interface with different components (support, heat exchanger plate) depending on orientation, maintaining securement effectiveness while using a unified design.
3Adaptability or versatility
If multiple unique endplate designs are produced, then each design can be tailored to specific orientations, but assembly and testing processes become more complex
Solution Approach 1:
The endplate with multiple connectors in different side regions serves as a universal component that can be used across different battery orientations and configurations. This eliminates the need for workers to handle multiple unique endplate designs during assembly and testing, simplifying operations while maintaining orientation-specific functionality.
Data Source
AI summary
An exemplary battery pack assembly includes an endplate with a first side region and a second side region opposite the first side region, a first connector in the first side region, and a second connector in the second side region. The first and second connectors each provide a connection point to secure the endplate to a support when a respective one of the first or second side regions is positioned proximate the support.