Battery Pack Coupling Protrusions and Holes for Injection Molding
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Solution Overview
Problem
Conventional battery packs are susceptible to structural deformation and separation due to external forces because the first and second cases are connected using adhesives, lacking a direct physical connection, which complicates their fabrication and installation in electronic devices.
Innovation Solution
A battery pack design featuring a first case with coupling protrusions and a second case with corresponding coupling holes, forming a locking structure that enhances bonding strength and allows easy injection molding, with additional features like guide walls, auxiliary holes, and isolation walls to secure battery cells and circuit modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the first and second cases are connected using adhesives, then the battery pack can be assembled, but the bonding strength is insufficient and the structure is susceptible to deformation and separation under external forces
Solution Approach 1:
The connection structure is segmented into coupling protrusions on the first case and corresponding coupling holes on the second case. This segmentation allows for a mechanical interlocking connection that distributes external forces across multiple discrete connection points, enhancing both bonding strength and structural reliability compared to a single adhesive bond.
Solution Approach 2:
Instead of using a continuous adhesive layer that relies on chemical bonding, the invention inverts the approach by using discrete mechanical features (protrusions and holes) that create physical interlocking. This inversion from chemical to mechanical bonding fundamentally resolves the strength and reliability issues.
2Strength
If a direct physical connection structure is designed between the first and second cases, then bonding strength is improved, but the fabrication complexity and difficulty of injection molding increase
Solution Approach 1:
The coupling protrusions are integrated directly into the injection molding process of the first case, combining the connection feature formation with the case manufacturing in a single step. This merging eliminates separate machining or assembly operations, maintaining ease of manufacture while achieving strong mechanical connection.
Solution Approach 2:
The coupling protrusions serve multiple functions: they provide mechanical connection strength, guide the alignment of the second case during assembly, and are formed as integral features of the injection molded part. This multi-functionality reduces the need for additional manufacturing steps while achieving the desired bonding strength.
Data Source
AI summary
A battery pack that allows easy application of injection molding in the formation of a battery case and is capable of improving fastening strength of the case components. For this purpose, the battery pack comprises a plurality of battery cells; a circuit module electrically connected to the plurality of battery cells; and a case accommodating the plurality of battery cells and the circuit module, wherein the case includes a first case shaped in the form of an open box and having a plurality of coupling protrusions formed thereon and a second case shaped in the form of an open box and having a plurality of coupling holes engaging with the plurality of coupling protrusions in order to couple the second case with the first case.