Arc Battery Housing Structure for Easier Manufacturing
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Solution Overview
Problem
The difficulty in manufacturing housings for batteries of special shapes, such as arc batteries, leads to increased costs and reduced production efficiency, as existing methods require complex stamping processes that are challenging to execute.
Innovation Solution
A housing design comprising two arc-shaped cover plates and a middle frame with perpendicular walls, which are easy to manufacture and connect to form an accommodating space, reducing the complexity and cost of producing arc battery housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If complex stamping processes are used to manufacture arc battery housings, then the housing can achieve the required arc shape, but the manufacturing difficulty and cost increase significantly
Solution Approach 1:
The housing is divided into three separate components: a middle frame and two cover plates. The middle frame provides the arc-shaped support structure while the cover plates can be flat or lightly curved. This segmentation allows each component to be manufactured using simpler processes, avoiding the need for complex stamping of the entire housing as a single piece.
Solution Approach 2:
The middle frame and cover plates are combined through connection structures (such as welding, bonding, or mechanical fastening) to form the complete housing assembly. This merging of simpler components achieves the overall arc shape functionality without requiring complex stamping of individual parts.
2Shape
If complex stamping processes are used to manufacture arc battery housings, then the housing can achieve the required arc shape, but the production efficiency decreases
Solution Approach 1:
By segmenting the housing into manufacturable components (middle frame and cover plates), each part can be produced independently using efficient, simple processes. This parallel manufacturing approach increases overall production efficiency compared to the sequential, complex stamping process required for monolithic arc-shaped housings.
Solution Approach 2:
The design changes the geometric parameters of individual components, allowing the middle frame to provide arc support while cover plates maintain simpler geometries. This parameter optimization enables faster manufacturing cycles and higher production throughput while maintaining the required arc shape of the complete housing.
3Ease of manufacture
If the housing is designed as separate components, then the manufacturing cost decreases, but the structural integrity may be compromised
Solution Approach 1:
The middle frame is designed with pre-integrated connection structures (such as tabs, recesses, or bonding surfaces) that are prepared in advance during its manufacturing. These preliminary features ensure strong, reliable connections when the cover plates are assembled to the middle frame, maintaining structural integrity while keeping individual components simple and cost-effective to manufacture.
Solution Approach 2:
The housing assembly functions as a composite structure where the middle frame (potentially metal or rigid plastic) and cover plates (possibly different materials) are combined. This composite approach allows each material to be optimized for its specific function while the connection between them provides the necessary structural strength, often at lower cost than using a single expensive material throughout.
Data Source
AI summary
This application provides a housing, an arc battery, and an electric device. The housing includes two cover plates and a middle frame, where the two cover plates are both arc shaped plates, the middle frame has two opposite openings in a first direction, and the two cover plates are configured to respectively cover the two openings, and the middle frame and the two cover plates jointly define an accommodating space. The two cover plates of the housing are both arc plates, and therefore the housing can be used for arc batteries. The housing is divided into two are cover plates and a middle frame that are separately disposed.