Battery Pack Hole Surface Roughness for Error Detection
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Solution Overview
Problem
The existing battery pack manufacturing process through injection molding faces increased defect rates and unclear criteria for determining forming errors, leading to prolonged condition setting times and potential safety and quality issues due to the decreased thickness of battery cases.
Innovation Solution
Incorporating regions around holes with distinct surface roughness to visually detect forming errors, allowing for quicker identification and correction of defects, thereby reducing the condition setting time and ensuring quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the thickness of battery case is decreased to meet slimming requirements, then the power supply time, size and weight are improved, but the defect rate of holes increases and manufacturing precision deteriorates
Solution Approach 1:
The patent applies local quality by creating a first region with different surface roughness characteristics compared to other regions of the battery case. This localized differentiation allows for visual detection of forming errors in holes without requiring increased overall thickness, thus resolving the contradiction between thinning the case and maintaining manufacturing precision.
2Manufacturing precision
If the condition setting time is increased to control forming error, then the manufacturing precision is improved, but the productivity decreases
Solution Approach 1:
The patent implements self-service by designing the battery case with a first region that automatically provides visual indication of forming errors through its distinct surface roughness. This self-indicating feature eliminates the need for extended condition setting time and complex inspection processes, allowing operators to quickly identify defective holes and maintain high productivity while ensuring manufacturing precision.
Data Source
AI summary
A battery pack includes a region spaced a certain distance apart from a hole of a battery case. The region is different in surface roughness from the other regions of the battery case, and thus, a forming error of the hole may be visually detected, so as to decrease a condition setting time for controlling the forming error.