Battery Waterproof Cradle Drainage System
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Solution Overview
Problem
Conventional battery systems with watertightly sealed outer cases require significant time and effort for assembly and maintenance, and their waterproof structures are prone to failure due to aged packing, allowing water ingress and leading to corrosion, electric leakage, and short circuits.
Innovation Solution
A battery system with a cradle-based drainage system that exposes the output lead and lead plate, featuring a drainage hole and channel to externally drain entering water, eliminating the need for sealing packing and maintaining a stable waterproof structure even under severe conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer case is completely sealed with packing, then waterproof performance is improved, but maintenance work becomes difficult and time-consuming
Solution Approach 1:
The outer case is divided into a case body and a separate waterproof cover that can be independently removed. This segmentation allows maintenance personnel to access the interior components (battery, connector) by simply detaching the cover, eliminating the need to open the entire sealed case structure. The waterproof cover acts as an independent maintenance access point, resolving the contradiction between maintaining sealed integrity and enabling easy maintenance.
Solution Approach 2:
The waterproof cover is extracted as a separate removable component from the main case structure. This extracted element serves dual purposes: maintaining waterproof sealing during normal operation while providing easy access during maintenance. The cover can be completely removed from the case body, allowing direct access to internal components without compromising the sealed structure of the remaining case.
2Reliability
If the outer case is completely sealed with packing, then waterproof performance is improved, but the packing ages and deteriorates allowing water entry
Solution Approach 1:
The waterproof cover incorporates a rubber sealing ring that provides a resilient sealing interface between the cover and case body. This elastomeric sealing element compensates for dimensional variations, thermal expansion, and minor misalignments that occur over time, maintaining waterproof integrity despite environmental aging. The flexible sealing ring prevents water infiltration even when the rigid case structures experience dimensional changes due to temperature cycling or material aging.
Solution Approach 2:
A rubber sealing ring is introduced as a flexible sealing element at the interface between the waterproof cover and case body. This flexible membrane maintains continuous contact and sealing pressure, adapting to dimensional changes and surface irregularities that develop over time. The elastomeric material's ability to deform and recover ensures sustained waterproof performance, preventing water entry paths that would otherwise form due to rigid structure degradation.
3Reliability
If the connector with output lead is watertightly fixed to the outer case, then waterproof performance is improved, but the structure becomes complicated
Solution Approach 1:
The connector and output lead assembly is integrated with the waterproof cover as a unified removable unit. The connector is positioned and fixed relative to the cover such that both components are simultaneously accessed when the cover is removed. This merging eliminates the need for separate sealing structures and attachment mechanisms for the connector, simplifying the overall design while maintaining waterproof integrity through the cover-case interface.
Solution Approach 2:
The waterproof cover serves multiple functions: it seals the case opening to prevent water entry, provides structural support for the connector assembly, and acts as a maintenance access door. By consolidating these functions into a single component, the design eliminates the need for separate sealing plates, connector mounts, and maintenance hatches, thereby reducing structural complexity while achieving comprehensive waterproof protection.
Data Source
AI summary
In a battery system, an output lead is exposed at an opening of an outer case, and the outer case accommodates a cradle mounting a lead plate and disposed at a fixed position. The cradle includes an upper plate allowing the lead plate to be disposed on the upper plate, a peripheral wall disposed around the lead plate, a drainage hole opened in the upper plate, and a drainage channel for water flowing from the drainage hole. The outer case is provided with a drainage opening allowing water flowing from the drainage channel to be externally drained. The lead plate includes a planar part disposed inside the peripheral wall, and a rising part crossing over the peripheral wall. Entering water flowing from the opening flows from the drainage hole and passes through the drainage channel to be externally drained out of the drainage opening of the outer case.