Battery Pack Lower Case Structure for Impact and Rainwater Protection
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Solution Overview
Problem
Existing battery packs are vulnerable to impact loads from flying objects during rough weather, leading to stress concentration and potential ingress of rainwater due to uniform case thickness, which is not addressed in prior art.
Innovation Solution
A power supply device with a housing design featuring a lower case with a side wall portion, an attachment portion, and a thick-walled protrusion at the boundary between the side wall and attachment portion, along with an inclined side wall, to distribute impact stress and prevent rainwater ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the thickness of the lower case is uniform, then the manufacturing process is simple, but stress concentrates at the boundary portion between the lower wall portion and side wall portion during impact loads from flying objects, causing cracks and rainwater ingress
Solution Approach 1:
The lower case features a thick-walled portion at the boundary between the lower wall portion and side wall portion, creating non-uniform thickness distribution. This local thickening concentrates stress at the reinforced boundary area during impact loads from flying objects, preventing stress concentration at vulnerable corners and avoiding cracks that would allow rainwater ingress, while maintaining relatively simple manufacturing processes
2Device complexity
If the side wall portion is vertical, then the structure is simple, but the impact load directly transfers to the storage batteries during typhoons
Solution Approach 1:
The side wall portion includes an inclined portion that slopes outward from the lower wall toward the upper wall. This inclined geometry acts as a cushioning structure that absorbs and redirects impact loads from flying objects during typhoons, preventing direct force transmission to the storage batteries housed within the housing, while adding minimal structural complexity
Data Source
AI summary
A power supply device includes a housing including an upper case and a lower case, and a plurality of storage batteries housed in the housing. The lower case includes a side wall portion configuring an outer periphery of the lower case, an attachment portion that is provided at an upper side of the side wall portion, and that is attachable to the upper case in a state in which the upper case is disposed at an upper side relative to a bottom surface of the storage batteries, and a thick-walled portion protruding toward an outer side of the lower case at a boundary portion between the side wall portion and the attachment portion.