Battery Pack Housing Segmentation for Waterproofing
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Solution Overview
Problem
Existing battery packs face challenges in achieving a lightweight and safe design while maintaining a waterproof structure, particularly when using high-energy density non-aqueous electrolyte battery modules in applications like electric vehicles, where moisture reactivity with lithium compounds poses safety risks.
Innovation Solution
A novel battery pack design featuring a housing with a unique fastening structure that includes a buffer member and partition walls to create separate spaces for moisture absorption, preventing moisture ingress and enhancing the sealing between the top, middle, and bottom portions, thereby ensuring improved waterproofing and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a housing structure is designed to be lightweight, then the weight of the battery pack is reduced, but the waterproofing performance deteriorates
Solution Approach 1:
The housing is divided into multiple portions (first, second, third portions) with separate fastening structures. Each portion has its own fastening portion with fastening holes, allowing modular assembly that maintains sealing integrity while using lighter materials and reducing overall weight compared to a monolithic housing structure.
Solution Approach 2:
Fastening members act as intermediary elements connecting the housing portions. These fastening members include fastening holes that align across portions, creating a sealed connection path that prevents moisture ingress while allowing the use of lightweight materials and reducing the need for heavy-duty sealing mechanisms.
2Ease of manufacture
If the housing structure is simplified for easy manufacture, then the manufacturing complexity is reduced, but the waterproofing capability deteriorates
Solution Approach 1:
The housing is segmented into multiple portions that can be manufactured separately using standard manufacturing processes, then assembled together. Each portion includes integrated fastening structures with fastening holes, eliminating the need for complex post-assembly sealing operations while maintaining waterproof integrity through the aligned fastening member connections.
Solution Approach 2:
The fastening function and sealing function are merged into a single integrated structure. The fastening portions of each housing portion include built-in fastening holes that serve both mechanical connection and sealing purposes, combining what would traditionally require separate fastening mechanisms and sealing elements into one unified component that is easier to manufacture.
3Volume of moving object
If fastening portions are closely spaced for compact design, then the volume is reduced, but the moisture absorption capability deteriorates
Solution Approach 1:
The fastening portions are arranged in a distributed pattern across multiple dimensions rather than being closely spaced in a single plane. The first, second, and third portions are positioned at different locations, and their fastening holes are aligned to create a three-dimensional sealing network that provides moisture absorption capability while maintaining a compact overall volume.
Solution Approach 2:
The housing is divided into multiple portions with fastening structures distributed throughout the structure rather than concentrated in one area. This segmentation allows moisture to be absorbed and managed at multiple discrete locations while maintaining a compact design, as each fastening portion can be optimally positioned for both space efficiency and moisture management.
Data Source
AI summary
A battery pack including a plurality of bare cells electrically connected to one another; and a housing including a bottom portion accommodating the bare cells therein, a middle portion mounted on the bottom portion, and a top portion on the middle portion, the top portion including a first fastening portion, and the middle portion including a second fastening portion facing the first fastening portion, and at least a portion of the first fastening portion or the second fastening portion is spaced apart from the other of the first fastening portion or the second fastening portion.