Battery Pack Case Maintenance Port and Cover Plate Assembly
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Solution Overview
Problem
Conventional battery pack cases require complete disassembly for maintenance, which is time-consuming, laborious, and poses challenges in reassembling for sealing, compromising safety and efficiency.
Innovation Solution
A battery pack case with a maintenance port and cover plate assembly that allows for component maintenance without disassembling the case, featuring a cover plate with a concave portion and outer gasket for controlled sealing, ensuring safety and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lower case and upper cover are completely disassembled for maintenance, then all components can be accessed, but the maintenance process becomes time-consuming and laborious
Solution Approach 1:
The battery pack case is segmented into a lower case, upper cover, and intermediate cover. The intermediate cover can be independently removed to access specific components (busbar, fan, fuse) without disassembling the entire case. This segmentation allows maintenance personnel to perform targeted maintenance operations quickly while leaving other components intact, thus reducing maintenance time while ensuring full accessibility to required components.
2Ease of operation
If the lower case and upper cover are completely disassembled for maintenance, then all components can be accessed, but the structural complexity of disassembly and reassembly increases
Solution Approach 1:
The case structure is divided into modular segments (lower case, upper cover, intermediate cover) that can be independently removed. The intermediate cover is designed as a separate maintenance port that provides direct access to key components. This modular segmentation simplifies the disassembly process by reducing the number of fastening points that need to be undone, thereby lowering disassembly complexity while maintaining full component accessibility.
3Ease of operation
If the lower case and upper cover are reassembled after disassembly, then the case can be closed, but ensuring sealing between large sealing surfaces becomes difficult
Solution Approach 1:
The sealing system is segmented into multiple smaller sealing interfaces (lower case-intermediate cover, upper cover-intermediate cover) rather than one large sealing surface. Each segment has its own sealing structure that is easier to align and seal properly. This segmentation of the sealing system ensures that each small sealing surface can be reliably resealed, thereby maintaining overall sealing reliability while facilitating easier reassembly.
Solution Approach 2:
Sealing structures (such as sealing rings or gaskets) are pre-installed on the intermediate cover and case surfaces before final assembly. This preliminary preparation of sealing elements ensures proper positioning and contact pressure when the case is reassembled, making it easier to achieve reliable sealing without requiring complex alignment procedures during reassembly.
4Loss of time
If a maintenance port with cover plate assembly is used, then maintenance can be performed quickly, but additional components (cover plate, gasket) are required
Solution Approach 1:
The intermediate cover itself serves as the maintenance port, eliminating the need for separate access mechanisms. The cover plate assembly integrates the sealing function into the intermediate cover structure, reducing the number of additional components needed while enabling quick maintenance access.
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
Enables quick and efficient maintenance of battery pack components without disassembling the case, ensuring effective sealing and enhancing the safety and operational efficiency of the battery pack.
Implementation Method 1
the cover plate abuts against the outer surface of the side wall by the first limiting portion, to form a first receiving chamber for receiving the outer gasket
Implementation Method 2
ensuring a sealing between the cover plate assembly and the side wall
Data Source
AI summary
The present application relates to a battery pack case and a battery pack, the battery pack case includes: a case body including an accommodating chamber and a side wall provided with a maintenance port communicating with the accommodating chamber; a cover plate assembly, detachably connected to an outer surface of the side wall, being capable of opening or closing the maintenance port and including a cover plate and an outer gasket stacked with each other. The cover plate includes a first concave portion recessed in a thickness direction of the cover plate and a first limiting portion surrounding an outer periphery of the first concave portion, and abuts against the outer surface by the first limiting portion to form a first receiving chamber, the outer gasket is disposed in the first receiving chamber and is closely contact with the first concave portion and the outer surface.