Battery Pack Case Interlocking Walls Prevent Molding Leakage
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Solution Overview
Problem
The existing battery pack molding process is inferior due to leakage of molding material from the coupling parts of the case, which compromises the structural integrity and reliability of the battery pack.
Innovation Solution
The battery case design features interlocking side walls with coupling parts, such as tabs and clips, that prevent the molding material from leaking by securely coupling the first and second side walls, ensuring a complete seal during the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the case is physically coupled to reinforce strength and protect the bare cell, then the reliability of the bare cell is improved, but the molding material leaks from the coupling parts causing inferior molding quality
Solution Approach 1:
The case is divided into multiple side walls (first side walls and second side walls) that are coupled together through coupling parts. This segmentation allows each side wall to be independently formed and then joined, creating a modular structure that maintains strength while enabling proper molding material containment through the interlocking coupling parts.
Solution Approach 2:
The coupling parts feature nested interlocking structures where protrusions from one side wall fit into corresponding recesses in adjacent side walls. This nesting creates a hierarchical structure where the coupling parts are integrated within the overall case structure, providing both mechanical strength and sealing functionality to prevent molding material leakage.
2Strength
If coupling parts are used to physically couple the case, then the structural strength is improved, but the coupling parts are not completely coupled allowing molding material to leak
Solution Approach 1:
The coupling parts are designed with pre-formed protrusions and recesses that are created during the case formation process. This preliminary action ensures that when the side walls are assembled, the coupling parts are already configured to interlock properly, achieving complete coupling and preventing molding material leakage without requiring additional assembly steps.
Solution Approach 2:
The coupling parts act as intermediary elements between adjacent side walls, with protrusions from one side wall serving as mediators that fit into recesses of neighboring side walls. This intermediary structure facilitates the connection between side walls, ensuring complete coupling while maintaining the overall structural integrity of the case.
Data Source
AI summary
A battery case including: first case body having a main wall and opposing side walls; a second case body including a second main wall and opposing side walls. The first and second side walls include coupling parts to be coupled together when the first and second case bodies are pressed together to form a space to receive a bare cell. The battery case can also include clips to couple the first and second side walls.