Battery Pack Handle Reinforcement for Fracture-Resistant Mounting
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Solution Overview
Problem
The integration of the handle with the box in battery packs leads to stress concentration and low structural strength at their connection, resulting in fractures and frequent replacements.
Innovation Solution
A battery pack design with a box featuring a first and second accommodation cavity, reinforced by protruding reinforcing portions, and a handle with movable connecting portions and grooves that accommodate these reinforcements, enhancing structural strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the handle is integrated with the box, then processing and mounting are facilitated, but stress concentration occurs at the connection part leading to fracture
Solution Approach 1:
The patent divides the connection structure into separate functional elements: the box body, the handle, and reinforcing portions. The handle is separated from the box by defining a second accommodation cavity that houses the handle and its connecting portion, allowing independent manufacturing and assembly while maintaining structural integrity through the reinforcing portions that distribute stress away from the connection interface.
Solution Approach 2:
The patent introduces reinforcing portions as intermediary structural elements between the box and handle. These reinforcing portions extend into the second accommodation cavity and work with the connecting portion to distribute and transfer loads, preventing stress concentration at the handle-box connection interface while facilitating assembly.
2Ease of operation
If the handle is integrated with the box, then mounting is simplified, but the connection part experiences low structural strength resulting in fracture
Solution Approach 1:
The connection structure is segmented into the handle body, connecting portion, and box body with a dedicated second accommodation cavity. This segmentation allows the handle to be mounted as a separate component while maintaining reliable connection through the reinforcing portions that provide structural support and stress distribution at the connection interface.
Solution Approach 2:
The patent adds a spatial dimension to the connection structure by extending reinforcing portions into the second accommodation cavity. This three-dimensional arrangement allows the connecting portion to move between positions while maintaining stable connection through the spatial distribution of reinforcing portions that provide support from multiple directions.
Data Source
AI summary
A battery pack and an electrical consumer are provided. The battery pack includes multiple battery cells, a box, and a handle. The box defines a first accommodation cavity and a second accommodation cavity, the second accommodation cavity is defined at a side of the first accommodation cavity, the multiple battery cells are accommodated in the first accommodation cavity, at least one reinforcing portion is disposed in the second accommodation cavity, and the at least one reinforcing portion protrudes from a top of the second accommodation cavity towards a bottom of the second accommodation cavity. The handle includes a handle body and a connecting portion. The connecting portion is connected with the handle body, the connecting portion defines at least one top-open groove at a top of the connecting portion, and the connecting portion is disposed in the second accommodation cavity.