Battery Pack Box Sealing for Side-Mounted Voltage Sampling
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Solution Overview
Problem
Traditional module-integrated battery packs have low grouping efficiency, complex structure, high cost, and complex production due to a low-voltage sampling structure that occupies installation space and requires additional insulation and protection, resulting in reduced integration and waterproof performance.
Innovation Solution
A battery pack design that integrates a battery box, battery module, sampling wire, and low-voltage connector, with a box sealing structure using a U-shaped sealing groove and sealing strip to save installation space, reduce insulation and protection parts, and enhance grouping efficiency and waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a low-voltage sampling structure is arranged above the cell, then the battery pack can perform sampling function, but it occupies installation space and reduces grouping efficiency
Solution Approach 1:
The low-voltage sampling structure is moved from the traditional vertical arrangement above the cell to a horizontal arrangement on the side wall of the battery box. This dimensional change allows the sampling structure to utilize previously unused side space, eliminating the occupation of installation space above the cell and thereby improving grouping efficiency while maintaining the sampling function.
Solution Approach 2:
The side wall of the battery box is transformed into a multi-functional surface that simultaneously serves as a structural boundary and a mounting surface for the low-voltage sampling structure. This allows the sampling function to be integrated into the existing battery box structure without requiring additional dedicated space, thus improving grouping efficiency.
2Reliability
If various insulations and protections are added above the battery pack, then the battery pack can achieve adequate insulation and protection, but the battery pack structure becomes complex
Solution Approach 1:
The insulation and protection functions are merged into the battery box structure itself rather than being added as separate components above the battery pack. The battery box is designed with integrated insulation layers and protective features, eliminating the need for additional independent insulation and protection components, thus simplifying the overall structure while maintaining adequate protection.
Solution Approach 2:
The battery box serves as an intermediary structure that provides both mechanical protection and electrical insulation between the battery cells and the external environment. By positioning the low-voltage sampling structure on the battery box side wall rather than above the cells, the battery box itself becomes the protective intermediary, reducing the need for additional protection layers and simplifying the structure.
3Ease of manufacture
If the battery pack uses traditional module-integrated design, then the battery pack can be assembled, but it results in low integration and high cost
Solution Approach 1:
The low-voltage sampling structure is merged with the battery box structure, forming an integrated assembly where the sampling components are built into the battery box rather than being separate modules. This integration reduces the number of discrete parts, simplifies assembly procedures, and lowers manufacturing costs while maintaining assembly capability.
Solution Approach 2:
The battery box is designed as a multi-functional component that simultaneously provides structural support, insulation, protection, and mounting for the low-voltage sampling structure. This universal design approach eliminates the need for separate dedicated structures for each function, improving integration while maintaining ease of manufacture through standardized multi-purpose components.
Data Source
AI summary
A battery pack includes a battery box, a battery module, a sampling wire and a low-voltage connector. The battery box is provided with an accommodating space for accommodating the battery module and a box sealing structure; the battery module is provided with a battery positive terminal post and a battery negative terminal post; and the battery positive terminal post and the battery negative terminal post of the battery module are connected with the low-voltage connector through the sampling wire for sampling the battery pack.