Seamless Battery Case Side Wall for Waterproof Space Saving
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Solution Overview
Problem
Existing battery case designs for in-vehicle batteries are inefficient in material usage and space allocation, leading to redundant members and reduced space for the battery due to the need for multiple components to ensure waterproofing.
Innovation Solution
A battery case side wall structure formed from a single seamless steel plate with integrated inner and outer flanges, eliminating holes and redundant members, and utilizing two steel plate members to enhance structural integrity and prevent water infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple members are used to ensure waterproofing in the battery case, then waterproof property is improved, but material waste increases and space for battery installation is reduced
Solution Approach 1:
The patent merges the waterproofing function with the structural frame members. The case side wall is formed as an integrated tubular structure with upper wall, inner wall, outer wall, and lower wall that is inherently watertight. This eliminates the need for separate waterproofing members while maintaining reliable waterproofing, thus reducing material waste without compromising the waterproof property.
2Reliability
If multiple members are used to ensure waterproofing in the battery case, then waterproof property is improved, but space for battery installation is reduced
Solution Approach 1:
The patent combines the waterproofing function into the structural case side wall itself. The tubular portion with closed cross-sectional structure forms an integrated watertight barrier that also serves as the structural framework. This eliminates redundant members that would otherwise occupy internal space, thereby maximizing the volume available for battery installation while ensuring reliable waterproofing.
3Loss of substance
If a seamless single steel plate structure is used for the case side wall, then material waste is reduced and space is increased, but manufacturing complexity may increase
Solution Approach 1:
The case side wall is segmented into functional zones (upper wall for sealing with upper cover, inner wall forming internal space, outer wall for external structure, lower wall for sealing with lower cover, and flanges for joining) but is manufactured as a single seamless steel plate structure. This segmentation of functions within a unified structure reduces material waste and maximizes space while the steel plate fabrication process keeps manufacturing complexity manageable.
4Volume of moving object
If the inner flange is erected at the lower edge of the inner wall, then height of internal space is increased, but structural integrity may be compromised
Solution Approach 1:
The inner flange is erected at the lower edge of the inner wall, concentrating the joining function at this specific location. This local placement maximizes the internal space height while the flange's structural design ensures adequate strength for joining the lower cover. The tubular structure's overall geometry provides additional structural support, maintaining integrity despite the optimized flange positioning.
Data Source
AI summary
The case side wall and the upper cover 24 are sealingly connected at the upper wall. The case side wall and the lower cover are sealingly connected by an inner flange. A first member of one steel plate of the case side wall forms a portion of the upper wall that is sealingly coupled to the upper cover, an inner flange, and an inner wall in one piece seamlessly and without holes. The inner wall serves as a waterproof wall, and even if water enters the tubular portion of the case side wall, it is possible to prevent water from entering into the battery accommodating space of the battery case.