Battery Case Segmentation for Thin Profile and Circuit Board Protection
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Solution Overview
Problem
Existing battery configurations for electric vehicles, such as straddle type vehicles, face challenges in achieving a thin profile while preventing circuit boards from being exposed to leaking electrolyte, which can compromise the battery's integrity and safety.
Innovation Solution
A battery case design with distinct cell accommodating portions and a separate board accommodating portion, utilizing partition walls to create a structural separation and reduce overall thickness, while ensuring the circuit board remains isolated from potential electrolyte leaks, using a modular design with half-case bodies and recessed portions to facilitate easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the battery is designed with a thin profile for straddle type vehicles, then the battery can be easily mounted and the rider can straddle the vehicle, but the circuit board may be exposed to leaking electrolyte from the battery cells
Solution Approach 1:
The battery case is divided into multiple compartments using partition walls. The first partition wall separates the battery cells from the circuit board, creating distinct spaces. This segmentation allows the battery to maintain a thin overall profile while providing physical isolation between the electrolyte-containing cells and the circuit board, preventing electrolyte exposure even when the battery is thin.
2Volume of moving object
If the battery case accommodates both battery cells and circuit board in a compact arrangement, then the overall battery size is reduced, but the circuit board may still be exposed to electrolyte leaks
Solution Approach 1:
The battery case is divided into multiple compartments using partition walls. The first partition wall separates the battery cells from the circuit board, creating distinct spaces. This segmentation allows the battery to maintain a thin overall profile while providing physical isolation between the electrolyte-containing cells and the circuit board, preventing electrolyte exposure even when the battery is thin.
Solution Approach 2:
The partition wall acts as an intermediary barrier between the battery cells and the circuit board. It physically separates the two components, preventing direct contact between the electrolyte and the circuit board while still allowing the battery to maintain a compact, thin design.
3Ease of manufacture
If the battery case uses a modular design with half-case bodies, then the assembly and disassembly become easier, but the structural complexity increases
Solution Approach 1:
The battery case is divided into two half-case bodies that can be separately assembled and disassembled. This segmentation into modular components facilitates easier manufacturing, assembly, and disassembly operations while the internal partition walls provide the necessary structural separation between cells and circuit board.
Solution Approach 2:
The partition walls are integrated within the half-case bodies, creating a nested structure where the partition walls form internal compartments within the overall battery case structure. This nesting approach provides functional separation without requiring entirely separate components.
Data Source
AI summary
A battery case includes a first cell accommodating portion that accommodates a first number of battery cells, and a second cell accommodating portion that accommodates a second number of battery cells, smaller than the first number. The second cell accommodating portion is shorter than the first cell accommodating portion in one of three directions parallel to sides of the battery case. The battery case further includes a board accommodating portion, which is adjacent to the second cell accommodating portion in the one of the three directions, and that accommodates a circuit board therein; a first partition wall arranged between the first cell accommodating portion and the board accommodating portion; and a second partition wall arranged between the second cell accommodating portion and the board accommodating portion. Thus, the thickness of the battery is reduced and the circuit board is separated from the battery cells.