Waterproof Battery Case With Integrated Sealing Plug
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Solution Overview
Problem
Conventional waterproof battery cases are not suitable for outdoor or humid environments due to moisture and dust ingress through gaps between the base and cover, and the sealing connectors are prone to damage, leading to a compromised waterproof effect and increased production costs.
Innovation Solution
A waterproof battery case design featuring a case body with a flange and recess for an elastic sealing member, and a waterproof plug with a convex rib that deforms to seal the hole, allowing wires to pass while preventing liquids and dust, and integrating the sealing mechanism with the case body for a harmonized appearance and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional sealing connector with multiple components is used to achieve waterproof effect, then the waterproof function is provided, but the production cost increases and the appearance becomes unharmonized
Solution Approach 1:
The patent integrates the sealing connector, wires, and waterproof plug into a single integrated structure. The waterproof plug is formed as one piece with the wires embedded therein, eliminating the need for separate sealing components and reducing assembly steps while maintaining waterproof effectiveness.
Solution Approach 2:
The integrated waterproof structure serves multiple functions simultaneously: the waterproof plug provides sealing, the embedded wires provide electrical connection, and the overall structure maintains a streamlined appearance. This multi-functional design reduces the number of separate components needed.
2Reliability
If a protruding sealing connector is used to ensure waterproof sealing, then the sealing effect is achieved, but the appearance becomes unharmonized and the connector is prone to external impact damage
Solution Approach 1:
The waterproof plug is integrated with the case body through the engaging sheet and engaging hole structure, creating a unified assembly that reduces protrusion. This integration strengthens the overall structure and reduces vulnerability to external impacts while maintaining the sealing function.
3Ease of manufacture
If gaps are left between base and cover for assembly, then the battery case can be manufactured easily, but liquid and dust can enter through the gaps
Solution Approach 1:
The patent employs an elastic sealing member that deforms to fill gaps between the base and cover. This flexible sealing approach maintains assembly ease while effectively preventing dust and liquid ingress through the gaps that would otherwise exist for manufacturing tolerance accommodation.
4Device complexity
If a waterproof plug with integrated wires is used, then the production cost is reduced and appearance is harmonized, but the wires must be embedded in the plug during manufacturing
Solution Approach 1:
The wires are embedded in the waterproof plug during the plug's formation process, before the plug is installed in the battery case. This preliminary action of embedding wires during molding simplifies the overall assembly process and reduces subsequent manufacturing steps.
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
Ensures effective sealing against liquids, moisture, and dust, protecting the electrode plates from rust and extending the battery case's service life, while being suitable for outdoor use and maintaining a harmonized appearance with reduced production costs.
Implementation Method 1
an elastic sealing member is disposed between adjacent surfaces of the base and the top cover
Implementation Method 2
the at least one convex rib is deformed due to being squeezed by the through hole
Data Source
AI summary
A waterproof battery case comprises: a case body including a base and a top cover, wherein adjacent surfaces thereof are correspondingly formed with a flange and a recess in which an elastic sealing member is mounted, the base is formed with an accommodation space allowing at least one battery to be accommodated, a stepped engaging hole and a through hole are formed between the outer wall of the base and the accommodation space; an electrode plate set, including at least one anode contact and at least one cathode contact accommodated in the accommodation space; and a waterproof structure, including an elastic waterproof plug allowing two wires to be integrally embedded therein, wherein a plug head at one end thereof is formed with a neck part having the circumference formed with at least one convex rib, the other end thereof is formed with an engaging sheet sleeved with the engaging hole.