Battery Pack Potting Clearance for Tight-Fit Cell Module Assembly
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Solution Overview
Problem
The existing battery pack designs face difficulties in performing a potting operation between the cell module and the box due to a lack of glue holding space, leading to glue overflow and inadequate bonding, which increases downtime and labor costs.
Innovation Solution
A battery pack design featuring a concave-convex fit between the cell module and the box, with a defined potting clearance that prevents glue overflow by accommodating convex ribs and limiting grooves, allowing for a snug fit and easy glue application, and additional sealant strips to secure the glue in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cell module is tightly fitted into the box to maximize space utilization, then the space utilization is improved, but the potting operation becomes difficult due to lack of glue holding space
Solution Approach 1:
The inner sidewall of the cavity is segmented into different functional zones: a first region containing limiting grooves for positioning, and a second region forming a potting clearance for glue application. This segmentation allows the cell module to be tightly positioned while maintaining space for potting operation.
Solution Approach 2:
Different regions of the cavity inner sidewall have different functional qualities: the first region provides mechanical positioning through limiting grooves, while the second region provides glue holding space. This local differentiation resolves the contradiction between tight fit and potting space.
2Ease of manufacture
If the cell module is loosely fitted in the box to provide space for potting operation, then the potting operation is facilitated, but the positioning precision and stability of the cell module deteriorates
Solution Approach 1:
The cavity inner sidewall is divided into distinct functional zones: positioning grooves for precise location and a separate potting clearance region. This segmentation enables both precise positioning and adequate glue application space.
Solution Approach 2:
The limiting grooves act as an intermediary mechanism that provides precise positioning while the adjacent potting clearance provides glue holding space. The grooves mediate between the cell module and the potting operation requirements.
3Ease of manufacture
If a large potting clearance is provided between the cell module and the box, then the glue holding space is improved, but the space utilization of the battery pack deteriorates
Solution Approach 1:
The cavity employs local quality differentiation where only specific regions (potting clearance areas) have increased space for glue application, while other regions maintain tight fit. This localized approach provides necessary glue space without compromising overall space utilization.
Solution Approach 2:
The cavity space is segmented into tight-fit regions for maximum utilization and localized potting clearance regions for glue application. This segmentation allows the battery pack to achieve both high space utilization and adequate potting space.
Data Source
AI summary
This application relates to a battery pack and a vehicle. The battery pack includes a box and a cell module. The box contains a cavity with an opening on one side. The cell module is accommodated in the cavity. A plurality of limiting grooves are spaced apart on an inner sidewall of the cavity. Convex ribs in one-to-one correspondence with and in fit with the limiting grooves are disposed on an outer sidewall of the cell module. A potting clearance that communicates with the opening is defined by a part of the inner sidewall of the cavity and a part of the outer sidewall of the cell module. The part of the inner sidewall of the cavity is configured to avoid the limiting grooves, and the part of the outer sidewall of the cell module is configured to avoid the convex ribs.