Vehicle Battery Case Clamp Mechanism for Seal Integrity
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Solution Overview
Problem
Existing vehicle battery cases face challenges with limited space for installation due to the need for long flange projections for bolt fastening, which increases the number of bolts required, leading to increased worker-hours for attachment and detachment, and potential deformation of resin components affecting sealability.
Innovation Solution
A vehicle battery case design featuring a clamp member that engages with the cover-side flange at one end and is fixed to the case body with a bolt at the other, eliminating the need for bolt holes in the flanges, reducing the number of bolts, and enhancing sealability through an inclined face that presses the flanges together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flanges are fastened with bolts, then the case body and cover are securely connected, but the flange projection length must be long enough for bolt arrangement, increasing space requirements
Solution Approach 1:
A clamp member is introduced as an intermediary component between the case body and cover. The clamp member has a first end that engages with the cover-side flange and a second end that is fixed to the case body with a bolt, thereby mediating the connection and eliminating the need for long flange projections while maintaining connection strength
Solution Approach 2:
The connection function is segmented into two parts: the clamp member engages with the cover-side flange at its first end and is fixed to the case body at its second end. This segmentation allows the bolt to be positioned away from the flange projection area, reducing the required flange projection length while maintaining secure connection
2Reliability
If the number of bolts is increased to prevent deformation and maintain sealability, then the sealability is improved, but the worker-hours for attaching and detaching the cover increase
Solution Approach 1:
The clamp member serves as a mediator that consolidates the fastening function. Instead of using multiple bolts directly on the flanges, a single bolt fixes the clamp member to the case body, while the clamp member's first end engages with the cover-side flange. This intermediary structure maintains sealability through the clamp member's pressing action while reducing the number of bolts from multiple to one, thereby reducing attachment and detachment time
3Weight of moving object
If the case body and cover are made of resin to save weight, then the weight is reduced, but the components may deform due to temperature changes at regions between bolts
Solution Approach 1:
The clamp member acts as a thermal buffer and mechanical stabilizer between the case body and cover. By positioning the bolt away from the flange projection area and using the clamp member as an intermediary, the design reduces concentrated thermal stress at flange regions. The clamp member's structure distributes forces more evenly, preventing deformation of the resin components while maintaining the weight-saving benefits of using resin materials
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates easy attachment and detachment of the cover while maintaining high sealability with a reduced number of bolts and preventing deformation of resin components, even in limited spaces, suitable for high-capacity batteries in vehicles.
Implementation Method 1
the clamp member includes an inclined face that is inclined in relation to abutting surfaces of the case-side flange and the cover-side flange; and since the clamp member is fixed to the case body with the bolt, the inclined face abuts and swages the case body, to thereby press the cover-side flange and the case-side flange against each other
Data Source
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AI summary
A battery case includes a case body (20) is provided in the rim of its opening with a flange (26) projecting outwards, a cover (22) with a flange (27) that covers the opening of the case body (20) and overlaps the flange (26), and a second plate (25) that clamps the flange (26) and the flange (27). The second plate (25) has a first end engaged with the flange (27) and a second end fastened to a first plate (24) with stud bolts (33), which is fixed to the case body (20), to thereby press the case body (20) and the cover (22) against each other.