Battery Pack Case Engagement to Prevent Impact Mispositioning
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Solution Overview
Problem
Existing battery packs face mispositioning issues between the upper-part case and the cell case, particularly when subjected to impacts like accidental drops, which can lead to adverse contact between the upper-part case and the control board.
Innovation Solution
The battery pack design incorporates engaging parts on the upper-part case and corresponding engaged parts on the cell case, which engage with each other to reduce the likelihood of mispositioning, even if the battery pack is dropped.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the upper-part case and cell case are designed without engaging parts, then the device complexity is reduced, but mispositioning occurs between the upper-part case and cell case under impact
Solution Approach 1:
The battery pack is divided into separate upper-part case and cell case components, each with dedicated engaging parts. This segmentation allows independent positioning features to be designed on each component, enabling precise engagement without complicating the overall structure.
Solution Approach 2:
Engaging parts are pre-designed and pre-positioned on both the upper-part case and cell case before assembly. These engaging parts protrude and extend in advance to guide and constrain the relative positioning of the two cases, preventing misalignment before impact occurs.
2Reliability
If engaging parts are added to prevent mispositioning, then the positioning accuracy is improved, but the device complexity increases
Solution Approach 1:
The engaging parts are integrated into the existing case structures rather than being separate components. The protruding engaging part on the upper-part case and the extending engaging part on the cell case are merged with the case bodies, achieving precise positioning without adding discrete parts or complex assembly steps.
Solution Approach 2:
The engaging parts serve multiple functions: they provide positioning guidance during assembly, maintain precise alignment during operation, and prevent mispositioning under impact conditions. This multi-functionality reduces the need for additional dedicated positioning mechanisms.
3Volume of moving object
If the upper-part case is positioned close to the control board, then the device compactness is improved, but the harmful effect of adverse contact increases under impact
Solution Approach 1:
The engaging parts create a preliminary constraint system that prevents the upper-part case from shifting or mispositioning before impact can occur. By establishing this preventive mechanism in advance, the design counteracts the potential harmful effect of adverse contact between the upper-part case and control board during impact events.
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Object To provide a technique in which the likelihood of mispositioning between an upper-part case and a cell case of a battery pack can be reduced. Solution A battery pack (2; 402; 602) includes an outer case (12; 412; 612), which comprises an upper-part case (14; 414) and a lower-part case (15; 415) fixed to the upper-part case (14; 414), and a cell case (80; 480; 780; 980), which is housed in the outer case (12; 412; 612). An engaging part (30) is provided on one of the upper-part case (14; 414) and the cell case (80; 480; 780; 980). An engaged part (110), with which the engaging part (30) engages, is provided on or in the other of the upper-part case (14; 414) and the cell case (80; 480; 780; 980).