Battery Pack Case Slidable Coupling and Injection Sealing
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Solution Overview
Problem
Existing battery pack cases are vulnerable to moisture permeation and have lengthy assembly times due to the use of screws or bolts, which can lead to damage and electric shock, and existing waterproof solutions like sheets or O-rings are not always effective.
Innovation Solution
A battery pack case design featuring slidable coupling protrusions and grooves on the upper and lower pack cases, with a bonding member injected into the coupling groove to provide a waterproof seal, allowing for easier assembly and effective moisture prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws or bolts are used to assemble the battery pack case panels, then the structural strength and reliability are improved, but the assembly time increases and the risk of moisture permeation through assembly gaps increases
Solution Approach 1:
The patent replaces the mechanical screw/bolt fastening system with an injection molding integration system. The case body and cover are molded with complementary protrusion and groove structures that interlock mechanically, while injection molding material fills the gaps to create a unified structure, eliminating the need for separate fasteners and reducing assembly steps.
Solution Approach 2:
The patent merges the fastening function and waterproofing function into the injection molding process itself. The injection molding material simultaneously bonds the case body and cover together while filling assembly gaps, combining multiple functions (structural bonding, sealing, and gap filling) into a single integrated process.
2Reliability
If screws or bolts are used to assemble the battery pack case panels, then the structural strength is improved, but the risk of moisture permeation through assembly gaps increases
Solution Approach 1:
The patent replaces the mechanical screw/bolt fastening system with an injection molding integration system. The case body and cover are molded with complementary protrusion and groove structures that interlock mechanically, while injection molding material fills the gaps to create a unified structure, eliminating the need for separate fasteners and reducing assembly steps.
Solution Approach 2:
The injection molding material acts as an intermediary substance that fills the assembly gaps between the case body and cover. This material serves dual purposes: providing structural bonding and creating a waterproof seal, thereby preventing moisture permeation through the assembly interface.
3Object-affected harmful factors
If waterproof sheets or O-rings are added to the assembled case, then the moisture prevention is improved, but the device complexity and assembly time increase
Solution Approach 1:
The patent merges the fastening function and waterproofing function into the injection molding process itself. The injection molding material simultaneously bonds the case body and cover together while filling assembly gaps, combining multiple functions (structural bonding, sealing, and gap filling) into a single integrated process.
Solution Approach 2:
The patent extracts the waterproofing function from separate components (waterproof sheets or O-rings) and integrates it directly into the case structure through injection molding. The waterproofing capability is built into the case body and cover designs with molded protrusions and grooves, eliminating the need for additional waterproofing components.
4Object-affected harmful factors
If multiple waterproof components are added to each assembled portion, then the moisture prevention is improved, but the manufacturing cost and assembly time increase
Solution Approach 1:
The patent merges the fastening function and waterproofing function into the injection molding process itself. The injection molding material simultaneously bonds the case body and cover together while filling assembly gaps, combining multiple functions (structural bonding, sealing, and gap filling) into a single integrated process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The slidable coupling and bonding member injection method significantly reduce assembly time and ensure moisture prevention, enhancing the safety and reliability of battery packs by providing a secure and waterproof connection.
Implementation Method 1
a bonding member (130) disposed on a portion at which the coupling protrusion and the coupling groove come into contact with each other and injected into the coupling groove
Data Source
AI summary
A battery pack case prevents moisture from being permeated into a battery pack with an easily assembled structure. The battery pack case includes an upper pack case and a lower pack case that are slidably coupled with each other. The upper pack case includes a coupling protrusion, and the lower pack case includes a coupling groove such that a bonding member is at portion at which the coupling protrusion and the coupling groove come into contact with each other.