Battery Pack Hook Reinforcement for Cover Coupling Reliability
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Solution Overview
Problem
Existing battery packs face challenges in maintaining a strong coupling force between the main frame and main cover, particularly when made of different materials like stainless steel and plastic, which can lead to potential disengagement of the hook mechanism under external forces.
Innovation Solution
The battery pack design incorporates reinforcement ribs and sub-frames that provide additional support to the coupling mechanism, ensuring the hook is securely engaged and resistant to external impacts by adjusting the contact points and material distribution, thereby enhancing the structural integrity and coupling force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the main frame and main cover are made of different materials (stainless steel and plastic), then manufacturing cost and ease of manufacture are improved, but coupling force and reliability deteriorate due to potential disengagement of the hook mechanism
Solution Approach 1:
The reinforcer is divided into multiple functional segments: a first rib providing initial support, connection ribs integrating the first rib to the sidewall portion, and a second rib extending toward the hook hole. This segmentation allows each component to perform its specific function while collectively solving the disengagement problem without requiring a complete redesign of the entire structure.
Solution Approach 2:
The reinforcer is strategically positioned adjacent to the hook hole where the coupling force is most critical. The first rib is located between the battery cell and sidewall portion, while the second rib specifically faces the hook hole to provide localized support exactly where needed to prevent disengagement, rather than uniformly reinforcing the entire structure.
2Reliability
If reinforcement structures are added to prevent disengagement, then reliability and coupling force are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The reinforcer is integrally formed with the sidewall portion of the main frame, merging two components into one. The connection ribs integrally connect the first rib to the sidewall portion, creating a unified structure that reduces the number of separate parts and assembly steps while still providing the necessary reinforcement to prevent disengagement.
Solution Approach 2:
The reinforcer serves multiple functions simultaneously: it strengthens the main frame structure, provides localized support to the hook mechanism, prevents disengagement under external forces, and maintains structural integrity without requiring additional separate components. This multi-functionality reduces overall device complexity despite the added reinforcement features.
Data Source
AI summary
A battery pack includes a main frame supporting a battery cell, the main frame including a hook hole and a reinforcer adjacent to the hook hole; and a main cover coupled to the main frame, the main cover including a hook inserted into and retained in engagement with the hook hole, wherein the reinforcer faces the hook hole with the hook therebetween to support the hook.