Overlapping Stepped Battery Pack Cover System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs for electrified vehicles require complete enclosure cover removal for servicing, which can lead to contamination and damage of non-serviceable components.
Innovation Solution
A cover system with overlapping first and second covers, each with a stepped design and seals, allows selective access to serviceable components while maintaining enclosure integrity, reducing the need to expose all components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single complete cover is used for the battery pack, then the enclosure integrity is maintained, but all components are exposed during servicing requiring complete cover removal
Solution Approach 1:
The single cover is divided into multiple segments (first cover and second cover) that can be independently removed. This allows service personnel to access only the specific compartment containing the serviceable electronic modules without removing the entire cover, thereby maintaining enclosure integrity and protecting non-serviceable battery assemblies from contamination while enabling targeted servicing of the electronic modules.
2Ease of operation
If a single complete cover is used for the battery pack, then the enclosure integrity is maintained, but the weight of the cover system increases
Solution Approach 1:
The cover system is segmented into multiple lightweight cover portions rather than a single heavy cover. Each cover portion can be independently removed and is optimized for its specific function, reducing the overall weight compared to a single complete cover that would need to provide full enclosure protection.
Solution Approach 2:
The cover system transitions from a static single-cover design to a dynamic multi-portion design where covers can be selectively removed and reinstalled. This dynamic capability allows for optimized weight distribution and reduces the need for excessive structural reinforcement that would be required in a single complete cover design.
3Ease of operation
If a single complete cover is used for the battery pack, then the structural simplicity is maintained, but selective access to components is not possible
Solution Approach 1:
The cover is segmented into multiple portions with defined overlapping relationships. The first cover and second cover are configured to overlap when assembled, creating a integrated appearance while maintaining independent removability. This segmentation enables selective access to different compartments without requiring complex mechanisms, as each cover portion can be independently manipulated.
Solution Approach 2:
The cover portions are designed with nested overlapping relationships where one cover portion overlaps another. This nesting arrangement allows for selective removal of individual covers while maintaining the overall structural integrity and aesthetic appearance of the enclosure, achieving selective access without excessive complexity.
Data Source
AI summary
A battery pack includes an enclosure assembly including a tray and a cover system secured relative to the tray. The cover system includes a first cover and a second cover that overlap one another. At least one of the first cover and the second cover includes a stepped design. Another battery pack includes an insert received within a tray and adapted to establish a first compartment and a second compartment within the tray. A first cover is positioned to cover the first compartment and a second cover is positioned to cover the second compartment.