Battery Box Angled Fastening Edges Buckling
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Solution Overview
Problem
Battery boxes made of plastic materials like polypropylene and ABS lose rigidity with increasing temperature and service life, leading to buckling under pressure, which compromises the contact between electrode plates and the electrolyte fleece, affecting battery performance.
Innovation Solution
The battery box design incorporates angled fastening edges on the side walls for attaching clamping elements that can adjust and absorb pressure changes, preventing buckling by providing a secure and adjustable stiffening mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the battery box is made of plastic material (polypropylene or ABS), then the manufacturing cost and ease of manufacture are improved, but the rigidity and structural stability deteriorate with increasing temperature and service life
Solution Approach 1:
The battery box combines plastic material (polypropylene or ABS) with metal stiffening elements to create a composite structure. The plastic provides ease of manufacture and corrosion resistance, while the metal stiffening elements provide the necessary rigidity and structural stability, especially under temperature and pressure conditions where plastic alone would deform or buckle.
2Ease of manufacture
If the battery box is made of plastic material, then the ease of manufacture is improved, but the reliability and resistance to buckling under pressure deteriorate over time
Solution Approach 1:
The plastic battery box is reinforced with metal stiffening elements forming a composite structure that maintains reliability and resistance to buckling under pressure and temperature conditions throughout the service life, while retaining the manufacturing advantages of plastic.
Solution Approach 2:
The stiffening structure is divided into multiple independent elements (stiffening ribs and/or stiffening rings) that are distributed throughout the battery box. This segmentation allows each element to independently resist local buckling pressures while maintaining overall structural integrity, and enables the stiffening elements to be added or modified without replacing the entire battery box.
3Strength
If stiffening elements are added to prevent buckling, then the rigidity and reliability are improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The stiffening function is divided into multiple separate elements (stiffening ribs and/or stiffening rings) that can be independently manufactured and then assembled into the battery box. This reduces the complexity of manufacturing each individual element and allows for flexible assembly, avoiding the need to manufacture complex integrated stiffening structures.
Solution Approach 2:
The stiffening elements are designed to be integrated into or attached upon the existing battery box structure. The stiffening ribs may be formed as integral parts of the box walls, while stiffening rings can be positioned within or upon the box, creating a nested configuration that adds rigidity without requiring complete structural redesign.
4Ease of manufacture
If the end walls are buckled due to loss of rigidity, then the manufacturing simplicity is maintained, but the contact pressure and battery performance deteriorate
Solution Approach 1:
The plastic battery box with metal stiffening elements maintains end wall rigidity throughout service life, preventing buckling that would otherwise occur with plastic alone. This ensures consistent contact pressure between electrode plates and electrolyte fleece, maintaining battery performance while retaining the manufacturing simplicity of plastic construction.
Solution Approach 2:
The stiffening elements are incorporated into the battery box design from the beginning (or can be added retroactively) to prevent end wall buckling before it occurs. This preliminary reinforcement ensures that the end walls maintain their shape and contact pressure under temperature and pressure variations throughout the battery's operational life.
Data Source
AI summary
The aim of the disclosure is to improve a battery box to the extent that, when manufactured and used in a simple manner, the performance of the battery is ensured also over a longer period of time and responses can be made to modifications to the box, to the pressures prevailing in the box, etc. This aim is achieved, according to the disclosure, by a battery box, for a block battery, for receiving at least one battery cell having an electrode plate, said battery box comprising a main body, which is made of plastics material and has two end walls, which extend substantially in parallel with the electrode plates, and two side walls, which extend substantially at a right angle to said end walls, the end walls and side walls each having a top edge and a bottom edge and being interconnected so as to form a corner edge and the side walls having on the outer faces thereof a fastening edge extending at an angle to the corner edge.