Battery Connector Plastic Seal Prevents Water Ingress
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Solution Overview
Problem
Existing battery packs face issues with water penetration through the connection window due to the degradation of rubber sealing materials, leading to potential electric shorts between components.
Innovation Solution
A battery connecting unit is designed with a plastic member and a metal terminal, where the plastic member is laser-welded to the upper housing, ensuring the metal terminal protrudes and is securely surrounded by the plastic member to prevent water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rubber sealing is used to seal the space between the upper housing and the electric terminal, then water penetration is prevented initially, but the rubber sealing degrades over time causing water to penetrate
Solution Approach 1:
The patent changes the material parameter from rubber to plastic, which has superior aging resistance and does not harden or corrode over time. The plastic member maintains its sealing properties throughout the service life, resolving the contradiction between initial water prevention and long-term durability.
Solution Approach 2:
The patent uses a composite structure combining plastic member and metal terminal, where the plastic provides sealing and corrosion resistance while the metal provides electrical conductivity. This composite approach maintains reliable water prevention throughout the product lifecycle.
2Reliability
If a rubber sponge is pressed by the upper case to shield the space, then water penetration is prevented, but the rubber sponge hardens and wears out during aging
Solution Approach 1:
The patent changes the material from elastic rubber sponge to rigid plastic member. The plastic member maintains its dimensional stability and shielding capability without hardening or losing its protective function over time, resolving the contradiction between shielding effectiveness and material stability.
3Ease of operation
If the electric terminal protrudes from the upper housing for electrical connection, then electrical functionality is enabled, but water can penetrate along the terminal toward the inside
Solution Approach 1:
The patent uses a plastic member that surrounds the electric terminal, creating a protective barrier that prevents water from penetrating along the terminal. The plastic member acts as a waterproof shell while allowing the terminal to protrude for electrical connection, resolving the contradiction between electrical functionality and water protection.
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
This configuration effectively prevents water penetration and subsequent electric shorts by maintaining a secure seal even as the rubber sealing degrades, ensuring the reliability of the battery pack.
Implementation Method 1
laser welding is applied to a plastic member and the upper housing made of plastic
Data Source
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AI summary
Disclosed is a battery connecting unit which is placed on a lower housing and protruding from an upper housing and thus is suitable for preventing water penetration from the outside of the upper housing, and a battery pack including the same. The battery connecting unit is electrically connected to a battery laminate between a lower housing and an upper housing of a battery pack and includes a plastic member configured to come into contact with the upper housing and a metal terminal inserted into the upper housing, wherein the plastic member partially surrounds the metal terminal, and wherein the metal terminal is made of a circular pillar. In addition, the battery pack includes the battery connecting unit.