Battery Connector Assembly With Integrated Waterproof Sealing
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Solution Overview
Problem
Existing battery connector assembly structures face challenges in achieving satisfactory water-tightness due to limitations in forming bolt holes in a bag shape, and sealing materials may not be effective in certain configurations, leading to compromised water-tightness.
Innovation Solution
The assembly structure includes a battery cover with a standing wall and a through-hole, a battery connector with a pilot hole, a fastener with a screw portion, and a waterproof section between the battery cover and a plate, ensuring the connector is fastened with the screw passing through the through-hole and pilot hole, and incorporating a waterproof section around the through-hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bolt hole is formed in a bag shape to achieve water-tightness, then water-tightness is improved, but device complexity increases and manufacturing difficulty increases when there is no space on the back side of the battery connector
Solution Approach 1:
The sealing function is segmented from the bolt hole structure. Instead of forming a complex bag-shaped hole in the plate, a separate waterproof seal member is introduced to perform the sealing function. This simplifies the plate structure to a flat plate with a simple through-hole, while maintaining effective water-tightness through the dedicated seal member positioned between the plate and battery connector.
2Reliability
If a sealing material is used to achieve water-tightness, then water-tightness is improved, but adaptability decreases when the form of the battery unit does not allow for sealing material application
Solution Approach 1:
A waterproof seal member in the form of a gasket or O-ring is used instead of traditional sealing materials. This flexible seal member can be installed in the groove formed by the battery connector and plate structure, providing effective sealing across different battery unit configurations without requiring specific forms or additional space for sealing material application.
3Reliability
If a complex assembly structure is used to ensure water-tightness, then water-tightness is improved, but ease of manufacture decreases
Solution Approach 1:
The sealing function is merged into the fastening structure itself. The waterproof seal member is positioned in the groove formed by the battery connector and plate, where it is naturally compressed during the fastening process. This integration eliminates the need for separate sealing installation steps, simplifying manufacturing while ensuring water-tightness.
Data Source
AI summary
An assembly structure of a battery connector, a battery unit, and a support structure of a battery unit each including the following: a battery cover storing a battery pack and including a standing wall provided with an opened through-hole extending from the outer side to the inner side; a battery connector including a pilot hole at a position corresponding to the through-hole; a fastener including screw and head portions; and a plate including an outer surface to which the head portion is fixed at a position corresponding to the pilot hole. The battery connector is fastened to the outer side of the standing wall by the fastener with the screw portion passing through the through-hole and the pilot hole from the inner side to the outer side, and a waterproof section disposed between the battery cover and the plate so as to surround the through-hole is further included.