EV Battery Pack Sealed Cover With Surface-Mounted Fasteners
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Solution Overview
Problem
Conventional electric vehicle battery packs are insufficiently sealed, leading to the risk of moisture infiltration and damage during exposure to rain or submersion, as fasteners often create pathways for water entry through holes in the cover.
Innovation Solution
The implementation of a sealed cover for electric vehicle battery packs with fasteners affixed to the surface rather than extending through the cover, and the use of seals to create a waterproof connection between the cover and frame, eliminating holes and reducing leakage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners extend through the cover to secure it to the frame, then the cover can be firmly attached, but holes are created in the cover that allow water and moisture to infiltrate the battery pack
Solution Approach 1:
A seal member (flexible element) is positioned between the cover and frame to prevent water infiltration through the attachment interface. The seal member deforms to accommodate the fastener holes while blocking moisture pathways, allowing firm attachment without compromising waterproofing.
Solution Approach 2:
The seal member acts as an intermediary element between the cover and frame, mediating the connection while blocking the harmful pathway for water infiltration. It transfers the attachment function while preventing moisture ingress through the fastener penetration points.
2Object-affected harmful factors
If the cover surface is made continuous and unbroken to prevent leakage, then waterproofing is improved, but fasteners cannot be securely attached to the cover
Solution Approach 1:
The seal member (flexible element) compensates for the discontinuities created by fastener holes, restoring the waterproof barrier while allowing fasteners to be attached. The flexible material deforms around the holes to maintain a continuous sealing surface.
Solution Approach 2:
The sealing function is separated from the structural attachment function. The seal member provides continuous waterproofing while fasteners provide discrete attachment points, allowing both requirements to coexist without compromising either waterproofing or fastener attachment capability.
3Ease of manufacture
If conventional battery pack covers are used, then manufacturing is simpler, but the covers are insufficiently sealed and risk leaking during rain or submersion
Solution Approach 1:
The seal member serves as an intermediary component that can be added to conventional cover designs to dramatically improve sealing reliability. This approach maintains ease of manufacture for the cover itself while adding a relatively simple sealing element to achieve reliable waterproofing.
Solution Approach 2:
The battery pack cover system becomes a composite structure combining the rigid cover, the flexible seal member, and the fastening system. This composite approach leverages the advantages of different materials - the rigidity of the cover, the flexibility and sealing capability of the seal member - to achieve both ease of manufacture and high sealing reliability.
Data Source
AI summary
Electric vehicle battery pack whose cover is more fully sealed against leakage. The cover is connected to the battery pack frame by fasteners that are affixed to the surface of the cover rather than being fastened through holes therein, or that are sealed to prevent leakage. The cover thus has no, fewer, or sealed holes formed within, and thus has fewer pathways for leakage or infiltration of moisture into the battery pack.