Battery Pack Case With Segmented Ribs For Thermal Contraction
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Solution Overview
Problem
Existing battery packs face issues with deformation due to cooling contraction after high-temperature molding and noise during assembly, particularly in the connection between the battery case and the main device, which affects the structural integrity and assembly precision.
Innovation Solution
The battery pack design incorporates a first case with a first base plate and first rib, featuring alternating thick and thin portions along its length to reduce contraction stress, and a second case with a second rib that forms a hooked connection with the first case, ensuring stable assembly and reduced noise by distributing stress evenly and preventing warpage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery case is molded at high temperature to ensure structural integrity, then the strength of the battery case is improved, but deformation occurs due to cooling contraction
Solution Approach 1:
The battery case is divided into multiple ribs (first rib, second rib, third rib, fourth rib) that are segmented along the longitudinal direction. Each rib contains uneven portions with varying thicknesses, creating localized segments that can independently manage thermal contraction stresses, preventing overall deformation while maintaining structural strength.
Solution Approach 2:
The ribs are designed with non-uniform thickness distribution, featuring thick portions and thin portions at specific locations. This local quality variation allows certain regions to be more rigid (thick portions for strength) while other regions provide flexibility (thin portions to accommodate contraction), resolving the contradiction between strength and deformation.
2Strength
If the battery case is molded at high temperature to ensure structural integrity, then the strength of the battery case is improved, but noise is generated during assembly
Solution Approach 1:
The case is segmented into multiple ribs with uneven thickness distributions. This segmentation allows the structure to flexibly absorb assembly stresses through localized deformation at the uneven portions, preventing noise-generating impacts while maintaining overall structural strength.
Solution Approach 2:
The uneven portions of the ribs act as pre-designed cushioning elements that anticipate and absorb assembly shocks before they propagate through the structure. The varying thickness creates compliant zones that cushion impacts during assembly, reducing noise while preserving the strength of the overall case structure.
3Stability of the object's composition
If the thickness of the battery case is increased to prevent deformation, then the structural stability is improved, but the complexity of the molding process increases
Solution Approach 1:
Instead of uniformly increasing the thickness of the entire battery case, the design applies local thickness variations only in specific rib regions where needed for stability. This localized approach achieves the required structural stability while avoiding the complexity and material waste associated with thickening the entire case structure.
Solution Approach 2:
The case structure is segmented into multiple ribs with selective thickness variations. This segmentation allows stability to be achieved through strategic thickening of specific rib portions rather than uniform thickening, simplifying the molding process by focusing material only where structurally necessary.
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 design effectively minimizes deformation and assembly noise, ensuring a stable and precise connection between the battery pack and the main device, enhancing the structural integrity and operational reliability of the battery pack.
Implementation Method 1
deformation due to cooling contraction after high-temperature molding of a battery case
Implementation Method 2
forms a hooked connection with the first case, ensuring stable assembly and reduced noise by distributing stress evenly and preventing warpage
Data Source
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AI summary
A battery pack is provided that comprises a battery cell, a first case and a second case coupled to each other to receive the battery cell. The first case comprises a first base plate arranged adjacent a main surface of the battery cell and a first side wall arranged to protrude from the first base plate along an edge portion of the first base plate. The first side wall is arranged adjacent a first side of the battery cell and comprises at least one support portion comprising alternating first and second portions, wherein the first portions are thicker than the second portions.