Battery Pack Rib Thickness Variation for Smooth Case Coupling
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Solution Overview
Problem
The existing battery pack assembly process is inefficient due to the thickness and design of ribs and coupling holes, which hinders smooth coupling of cases and can lead to structural issues during assembly.
Innovation Solution
The battery pack design involves reducing the thickness of certain rib portions and truncating the outermost portion of the first case to facilitate easier coupling of the second case, using a rib structure with sub-ribs and extending sub-ribs to create a coupling passage that allows for smooth engagement of coupling bosses with coupling holes, enhancing the coupling force and preventing separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the rib thickness is reduced to facilitate coupling, then the ease of coupling is improved, but the structural strength may be compromised
Solution Approach 1:
The rib structure employs varying thicknesses at different locations - thinner at the coupling end to facilitate insertion of coupling bosses, and thicker at the root to maintain structural strength. This local variation in geometry allows the rib to serve dual functions: ease of assembly and structural integrity.
Solution Approach 2:
The rib is divided into multiple segments with different thicknesses - a first rib portion with greater thickness for strength, and a second rib portion with reduced thickness for coupling facilitation. This segmentation allows each portion to be optimized for its specific function.
2Ease of operation
If the outermost portion of the first case is truncated to enable smooth coupling, then the ease of coupling is improved, but the structural完整性 may be compromised
Solution Approach 1:
The outermost portion of the first case is pre-truncated to create an opening that facilitates the initial insertion of coupling bosses. This preliminary modification to the case geometry enables smooth coupling while the coupling bosses and ribs provide subsequent structural reinforcement.
3Ease of operation
If the rib thickness is uniformly reduced, then the ease of coupling is improved, but the resistance to coupling force is reduced
Solution Approach 1:
The rib employs non-uniform thickness distribution - thinner at the coupling end to facilitate insertion, and thicker at the root to resist coupling forces. This local variation allows the rib to serve dual functions: ease of assembly and force resistance.
Data Source
AI summary
In a battery pack according to the embodiment of the present invention, when coupling bosses of a second case are coupled to coupling holes of a first case, the first case and the second case can be easily coupled to each other by reducing the thicknesses of some portions of a rib having the coupling holes before the coupling bosses are coupled to the coupling holes. In addition, the first case and the second case can be smoothly coupled to each other at the initial step of coupling the coupling bosses and the coupling holes to each other by opening the outermost portion of the first case facing the top end of the rib having the coupling holes.