Waterproof Battery Pack Separator Case Design
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Solution Overview
Problem
Conventional battery packs for electric bicycles often fail to prevent water penetration when exposed to moisture for extended periods, as water seeps through gaskets or gaps between the battery cases.
Innovation Solution
A battery pack design featuring a lower case, battery cell, protection circuit board, upper case, and a separator case with a waterproof layer and reinforcing layers, along with an elastic separator case that extends between the cases, forming stepped portions and discharge grooves to prevent water ingress and facilitate discharge, ensuring effective waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gasket is used between battery pack cases to prevent moisture penetration, then waterproofing is improved, but water still penetrates through the gasket or gaps between the gasket and battery pack cases during prolonged exposure
Solution Approach 1:
The waterproofing system is segmented into multiple functional layers: a separator extending between the upper and lower cases to block water pathways, a waterproof layer on the separator's upper surface for direct water resistance, and reinforcing waterproof layers at critical locations. This segmentation creates multiple barriers that prevent water penetration even when one layer is compromised.
Solution Approach 2:
The separator acts as an intermediary component between the upper and lower battery pack cases. It physically divides the internal space and serves as a medium through which the waterproof layer and reinforcing layers are applied, creating an intermediate barrier that blocks water pathways without requiring direct contact between the cases.
2Reliability
If a separator case with multiple waterproof layers is added to prevent water penetration, then waterproofing reliability is improved, but the device complexity increases
Solution Approach 1:
The separator serves multiple functions simultaneously: it divides the internal space of the battery pack, provides a substrate for attaching waterproof layers, and acts as a structural element that blocks water pathways. The waterproof layer and reinforcing layers are integrated onto the separator, creating a multi-functional assembly that reduces the need for separate waterproofing components.
Solution Approach 2:
The waterproof layers are nested onto the separator structure. The waterproof layer is formed on the upper surface of the separator, and the reinforcing waterproof layer is integrated at the gap between the separator and the lower case. This nesting approach consolidates multiple waterproofing functions into a single integrated component rather than requiring separate layered assemblies.
Data Source
AI summary
A battery pack for an electric bicycle is disclosed. In one embodiment, the battery pack includes i) a lower case having a top, a bottom and an interior space formed between the top and bottom and ii) a battery cell placed in the interior space of the lower case, wherein the battery cell has first and second surfaces opposing each other, and wherein the first surface of the battery cell is closer to the bottom of the lower case than the second surface of the battery cell. The battery pack may further include i) a protection circuit board mounted on the second surface of the battery cell and placed in the interior space of the lower case, ii) an upper case formed over the top of the lower case and iii) a separator case formed between the protection circuit board and the upper case.