Battery Housing Protrusion Positioning for Leakage Prevention
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Solution Overview
Problem
Conventional battery housing flange structures occupy internal space, reduce energy density, and are prone to weld deviations leading to liquid leakage and increased costs.
Innovation Solution
A housing design featuring a first and second housing with protrusions on the second housing that accommodate and contact the inner surface of the side wall for precise positioning, eliminating the need for a conventional flange structure, thus preventing liquid leakage and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a flange structure is used for positioning the cover and housing, then the positioning function is achieved, but the internal space of the battery is occupied, reducing energy density
Solution Approach 1:
The patent transitions from a two-dimensional flange structure to a three-dimensional protrusion structure that extends into the internal space of the housing. The protrusion has a specific cross-sectional shape (circular, oval, triangular, square, pentagonal, or fan-shaped) and height (not greater than 50mm), utilizing the vertical dimension to achieve positioning without requiring a large lateral flange structure. This dimensional transformation allows the positioning element to occupy minimal internal space while maintaining effective positioning function.
Solution Approach 2:
Instead of using a comprehensive flange structure around the entire perimeter, the patent employs localized protrusions at specific positions on the second housing. These protrusions are strategically placed to provide necessary positioning and support functions only where required, rather than uniformly across the entire structure. This localized approach minimizes the overall internal space occupation while maintaining structural integrity and positioning accuracy.
2Strength
If a flange structure is used for positioning, then the connection is achieved, but weld deviation occurs due to low positioning precision, leading to liquid leakage
Solution Approach 1:
The protrusions are pre-formed on the second housing during the molding process, establishing precise positioning features before the welding operation. This preliminary positioning action ensures that the cover and housing are correctly aligned prior to welding, preventing weld deviation. The protrusions act as mechanical guides that constrain the relative position of the components, making the welding process more accurate and reliable.
Solution Approach 2:
The patent replaces the mechanical flange-based positioning system with a protrusion-based positioning system that provides superior precision. The protrusions with their specific geometric shapes and dimensions create more accurate mechanical constraints compared to traditional flange structures. This mechanical substitution improves positioning precision from the flange level to the protrusion level, thereby preventing weld deviation and ensuring proper sealing.
3Strength
If a flange structure is used for positioning, then the structural support is achieved, but the raw material costs increase
Solution Approach 1:
The patent merges the positioning function and the structural support function into a single integrated protrusion structure. The protrusions are formed as integral parts of the second housing during the molding process, combining multiple functions (positioning, support, and structural integrity) into one element. This eliminates the need for separate flange structures and additional positioning components, thereby reducing the total quantity of raw materials required while maintaining structural support capabilities.
Solution Approach 2:
The patent discards the traditional flange structure that consumes excessive raw materials and replaces it with a more efficient protrusion structure. By eliminating the flange structure, the patent recovers the raw material that would have been used for the flange, reducing overall material consumption. The protrusions provide equivalent or superior functionality with significantly less material, achieving both cost reduction and energy density improvement.
Data Source
AI summary
A housing includes a first housing and a second housing. The second housing is provided with at least one protrusion, and the first housing includes a bottom wall and a side wall. The side wall is disposed on a peripheral edge of the bottom wall to form an accommodating space together with the bottom wall. The second housing is disposed on a side of the side wall away from the bottom wall, and the at least one protrusion is accommodated in the accommodating space and comes in contact with an inner surface of the side wall.