Battery Top Cover Handle Mounting to Prevent Cracking
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Solution Overview
Problem
The top cover of batteries is prone to damage due to repeated stress concentration from the carrying handle, leading to potential cracking and water ingress into the battery compartment.
Innovation Solution
A top cover design featuring independent connecting seats and rods that distribute the force of the carrying handle away from the cover body, incorporating threaded connections and limiting bulges to secure the handle and reduce stress concentrations, along with cushioning elements to absorb impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the carrying handle is directly attached to the cover body, then the structure is simple, but the repeated stress concentration causes cracking and damage
Solution Approach 1:
The carrying handle attachment structure is segmented into multiple components: connecting seats mounted on the cover body, connecting rods extending through the cover, and the handle itself. This segmentation distributes the attachment points and stress paths, preventing stress concentration at any single location on the cover body.
Solution Approach 2:
Connecting rods serve as intermediary elements between the carrying handle and the cover body. These rods transmit the lifting forces away from the cover body surface, acting as mediators that protect the cover from direct stress concentration while maintaining the structural connection.
2Reliability
If connecting seats and rods are added to distribute force, then the resistance to cracking is improved, but the device complexity increases
Solution Approach 1:
The connecting seats serve multiple functions: they provide mounting points for the connecting rods, distribute the attachment loads across the cover body surface, and maintain structural integrity. This multi-functionality reduces the need for additional specialized components, balancing reliability improvement with controlled complexity.
3Force
If the carrying handle exerts force directly on the cover body, then the force transmission is direct, but the stress concentration leads to water ingress
Solution Approach 1:
The connecting rods act as intermediaries that redirect the force transmission path away from the cover body. By channeling the lifting forces through the rods to attachment points on the cover body, the system maintains efficient force transmission while preventing stress concentration that would compromise the cover's water-tightness.
Solution Approach 2:
The connecting seats are pre-installed on the cover body to provide reinforced attachment points before the carrying handle is attached. This beforehand reinforcement creates stress distribution paths that prevent cracking and maintain water-tightness under repeated lifting loads.
Data Source
AI summary
A top cover includes a first cover plate, a first side plate, and a second side plate. The first side plate and the second side plate are opposite to each other and connected to one side of the first cover plate. A first through-hole and a second through-hole opposite to each other are created on the first side plate and the second side plate respectively. The first connecting seat is connected to a surface of the first side plate, the surface being oriented toward the second side plate.