Battery Pack Housing Structure for Impact and Short-Circuit Resistance
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Solution Overview
Problem
The reliability of battery packs is compromised due to structural weaknesses, which can lead to damage and short circuits under external impacts, and there is a need to enhance their structural strength and safety performance.
Innovation Solution
A battery pack design featuring a stronger connecting component that disperses impact forces, combined with a sealing component and filler to prevent moisture and impurities from causing short circuits, and additional structural elements like rib structures and brackets to enhance stability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack uses a conventional housing structure without reinforced connecting components, then the device complexity is lower, but the reliability and structural strength are insufficient under external impacts
Solution Approach 1:
The connecting component is constructed as a composite structure integrating a connecting plate and reinforcing ribs formed as an integrated unit. This composite design combines the flat connecting plate for basic attachment with three-dimensional reinforcing ribs that extend from the plate surface, creating a hybrid structure that leverages both the simplicity of a flat connection and the strength of ribbed reinforcement, thereby improving reliability without proportionally increasing complexity
Solution Approach 2:
The connecting component is segmented into functional zones: a connecting plate for attachment to the first housing, reinforcing ribs extending from the plate for structural strengthening, and a connecting portion for joining the second housing. This segmentation allows each zone to specialize in its function while being formed as an integrated component, improving structural performance without requiring multiple separate parts
2Reliability
If the second housing is closely attached to the first top wall without spacing, then the housing structure is simpler, but there is no accommodation space for components and impact force cannot be effectively dispersed
Solution Approach 1:
The design introduces a spatial dimension by creating a spaced relationship between the second housing and the first top wall along the first direction. This spacing generates a three-dimensional accommodation space within the housing structure, allowing placement of circuit boards and other components. The connecting component's ribs extend into this space to provide reinforcement, transforming a two-dimensional attachment problem into a three-dimensional structural solution that disperses impact forces more effectively
Solution Approach 2:
The connecting component with its reinforcing ribs is installed beforehand to create a cushioning structure between the first housing and second housing. The ribs act as shock-absorbing elements that distribute impact forces before they reach critical components, providing preemptive protection against damage from external impacts while maintaining the spaced configuration for component accommodation
3Reliability
If the circuit board and busbar connections are exposed without sealing, then the manufacturing process is simpler, but the risk of short circuits from moisture and impurities increases
Solution Approach 1:
The sealing component is merged with the circuit board assembly by directly mounting the sealing component onto the circuit board. This integration combines the electrical connection function of the busbar with the protection function of the sealing component into a single assembled unit. The busbar connects to terminals on the circuit board while the sealing component simultaneously covers these connection points, eliminating the need for separate sealing operations and reducing manufacturing complexity while ensuring protection against moisture and impurities
Data Source
AI summary
A battery pack includes a first housing, a second housing, a cell module, and a plurality of connecting components. The first housing includes a first top wall. The second housing is accommodated in the first housing and connected to the first housing. The second housing and the first top wall are spaced apart along a first direction. The cell module is accommodated in the second housing. The connecting component is connected to the first top wall and the second housing. A structural strength of the connecting component is greater than structural a strength of the second housing.