Battery Protection Pack Sealing Structure for Airtight Bolt Assembly
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Solution Overview
Problem
In high voltage battery protection packs, the weld region between the lower case and bush is not airtight, leading to moisture penetration, screw loosening, and increased working time due to the need for manual insertion of the bush into the gasket, which also results in quality issues during transportation.
Innovation Solution
The design includes a coupling plate on the upper case with spaced coupling holes, a lower case with a connecting plate and weld bolts, and a gasket with protection holes, where the weld bolts are welded to the connecting plate, and the gasket is compressed by an assembly nut to ensure airtight contact between the upper and lower cases, eliminating the need for a bush and improving airtightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a weld bolt and nut are welded through a hole in the lower case to ensure structural connection, then the structural strength is improved, but the airtightness deteriorates because the weld region cannot ensure perfect sealing
Solution Approach 1:
The patent separates the connection function and sealing function into different components. The weld bolt provides structural connection through the hole, while a separate bush component with integrated gasket provides the sealing function. This segmentation allows each component to optimize its specific function without compromising the other.
Solution Approach 2:
The bush acts as an intermediary component between the weld bolt head and the gasket. It fills the gap created by the weld hole and provides a sealed interface. The bush transmits both the mechanical connection force and the sealing requirement, resolving the contradiction between structural strength and airtightness.
2Reliability
If a bush is added to ensure airtightness and prevent screw loosening, then the reliability is improved, but the device complexity increases due to the need for additional manual insertion operations
Solution Approach 1:
The bush and gasket are merged into a single integrated component. The bush includes an axial groove that receives the gasket, eliminating the need for separate manual insertion operations. This merging reduces assembly complexity while maintaining the reliability benefits of both components.
Solution Approach 2:
The gasket is pre-positioned within the axial groove of the bush during bush manufacturing. This preliminary action ensures the gasket is already in place before the bush is installed, eliminating the need for separate manual gasket insertion operations and reducing assembly complexity.
3Reliability
If a bush is forcibly inserted into the gasket to ensure coupling, then the connection reliability is improved, but the working time increases due to additional manual operations
Solution Approach 1:
The gasket is pre-installed into the axial groove of the bush during bush manufacturing. This preliminary action eliminates the need for separate manual gasket insertion operations during assembly, reducing working time while ensuring the gasket is properly positioned for reliable coupling.
Solution Approach 2:
The bush and gasket are combined into a single integrated component with the gasket embedded in the bush's axial groove. This merging ensures the components remain coupled as a single unit during assembly, eliminating the need for separate insertion operations and reducing working time.
4Ease of manufacture
If the bush and gasket are kept separate to simplify manufacturing, then the ease of manufacture is improved, but the quality problems increase due to separation during transportation
Solution Approach 1:
The bush and gasket are merged into a single integrated component with the gasket embedded in the bush's axial groove. This merging ensures the components remain coupled as a single unit during manufacturing, storage, and transportation, eliminating quality problems related to separation while maintaining manufacturing simplicity.
Solution Approach 2:
The gasket is nested within the axial groove of the bush, creating a nested structure where one component is housed within another. This nesting ensures the components remain coupled and protected during handling and transportation, preventing separation issues while keeping the manufacturing process simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances airtightness performance, reduces working time, and minimizes quality defects by eliminating moisture penetration paths and the need for manual bush insertion, resulting in a more reliable and cost-effective battery protection pack.
Implementation Method 1
a lower case in which a plurality of weld bolts passing through the coupling holes of the upper case are welded to an upper portion of a connecting plate
Implementation Method 2
a gasket which seals a space between the upper case and the lower case
Implementation Method 3
as a gap between the head part of the weld bolt and the assembly nut decreases, the gasket may be compressed, and the upper and the lower cases may be pressed against each other
Data Source
AI summary
A high voltage battery protection pack according to one embodiment of the present invention includes an upper case including a coupling plate protruding along an outer circumferential surface of the upper case and a plurality of coupling holes formed in the coupling plate to be spaced apart from each other, a lower case in which a connecting plate having a shape corresponding to the coupling plate and including a weld groove formed by partial engraving is formed to protrude from an outer circumferential surface of the lower case, a weld nut which is disposed between the upper case and the lower case to maintain an axial force and is welded to the weld groove of the connecting plate, an assembly bolt which passes through the coupling hole of the upper case and is insertion-coupled to the weld nut, and a gasket which seals a space between the upper case and the lower case.