Battery Pack Outer Case Structure for Insulation and Rigidity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs face challenges in achieving both electric insulation and structural safety, particularly due to the use of rigid metal outer cases that require additional insulation structures, increasing manufacturing complexity and cost.
Innovation Solution
A battery pack design featuring a plastic outer case manufactured through injection molding, divided into unit parts interconnected with unit steel pipes, which provides electric insulation and enhances structural stability without additional insulation components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid metal outer case is used to support the heavy load of multiple battery cells, then structural rigidity and safety are improved, but electric insulation between the outer case and battery cells deteriorates, requiring additional insulation structures
Solution Approach 1:
The outer case is constructed using a composite structure combining metal reinforcement members embedded within a plastic housing. The metal members (steel pipes or angles) provide structural rigidity and load-bearing capacity, while the plastic material provides electric insulation. This composite approach allows the case to simultaneously support heavy battery cell loads while maintaining electrical isolation between the metal components and battery cells.
Solution Approach 2:
Instead of making the entire outer case from insulating material, metal reinforcement members are strategically positioned only where structural strength is needed - such as at corners, along edges, or at load-bearing points. The plastic material fills the remaining spaces, providing insulation where required. This localized application of different materials optimizes both strength and insulation properties.
2Object-affected harmful factors
If additional insulation structures or separate insulation components are applied between the outer case and battery cell, then electric insulation is improved, but manufacturing steps, tact time, and production cost increase
Solution Approach 1:
The structural support function and electric insulation function are merged into a single integrated outer case structure. The plastic housing and embedded metal reinforcement members work together to simultaneously provide mechanical strength and electrical isolation, eliminating the need for separate insulation components or additional assembly steps.
Solution Approach 2:
The outer case structure serves multiple functions simultaneously: it provides structural support for heavy loads, maintains electrical insulation between metal components and battery cells, and offers protective enclosure. This multi-functionality reduces the overall component count and simplifies manufacturing.
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
This design secures electric insulation and improves structural stability, reducing manufacturing steps, tact time, and production costs by eliminating the need for additional insulation structures, while maintaining mechanical integrity.
Implementation Method 1
securing electric insulation between the outer case and electric components
Implementation Method 2
improved structural rigidity and safety to firmly support multiple battery cells
Data Source
AI summary
Discussed is a battery pack that may include: a plurality of battery cells; an outer case configured to store the plurality of battery cells and including a plurality of unit parts disposed to extend in a first direction of the plurality of battery cells; and a reinforcement member configured to interconnect the plurality of unit parts and configured to be inserted into the plurality of unit parts such that a surface of the reinforcement member does not contact the plurality of battery cells.