Battery Pack Side-Wall Sealing for Easier Module Replacement
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Solution Overview
Problem
Existing battery packs in electrified heavy-duty vehicles face challenges with complex and prone-to-leakage sealing solutions, requiring long seals and complicating module replacement.
Innovation Solution
A battery pack design featuring a cover plate sealingly joined to the side wall with fastener devices outside the cover plate, securing battery modules and sealing through holes, reducing the need for long seals and allowing module replacement without removing the cover plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover plate is used to sealingly close the side wall, then the sealing performance is improved, but the device complexity increases due to the need for additional fastener devices and seal arrangements
Solution Approach 1:
The patent merges the fastening function and sealing function into a single integrated fastener device. The fastener device simultaneously secures the cover plate to the side wall and provides sealing through its structure, eliminating the need for separate seal components and reducing overall system complexity while maintaining reliable sealing performance.
Solution Approach 2:
The fastener device is designed to perform multiple functions: it mechanically fastens the cover plate to the side wall structure and simultaneously provides sealing functionality. This multi-functional design reduces the number of components needed and simplifies the overall sealing solution while ensuring reliable sealing performance.
2Reliability
If long seals are used to prevent water ingress, then the sealing reliability is improved, but the manufacturing precision requirements increase and the device complexity increases
Solution Approach 1:
The patent employs a short seal integrated into the fastener device rather than a long continuous seal. This short seal is sufficient for its specific function of sealing the through hole, reducing manufacturing precision requirements and simplifying installation while maintaining effective protection against water ingress.
3Strength
If fastener devices are positioned inside the cover plate, then the structural integrity is improved, but the ease of operation decreases due to complicated module replacement procedures
Solution Approach 1:
The patent segments the fastening system into removable fastener devices that can be independently accessed and operated. The fastener devices are positioned such that they can be easily removed to allow battery module replacement, and then reinstalled to restore structural integrity. This segmentation enables simple module replacement while maintaining structural strength when the fasteners are installed.
4Ease of manufacture
If multiple through holes are created for fastener devices, then the ease of manufacture is improved, but the reliability decreases due to increased potential leakage points
Solution Approach 1:
The fastener devices are designed to be self-sealing, where the act of inserting and tightening the fastener automatically seals the through hole without requiring separate sealing operations. This self-service sealing mechanism maintains high sealing reliability while allowing multiple through holes for ease of manufacturing and assembly.
Data Source
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AI summary
A battery pack (22) comprising a housing (24) including a side wall (26), the side wall (26) comprising a plurality of through holes (38); a plurality of battery modules (44) accommodated inside the housing (24); a plurality of fastener devices (58) securing the battery modules (44) to the side wall (26), each fastener device (58) passing through a respective through hole (38) and sealingly closing the through hole (38); and a cover plate (40) sealingly joined to the side wall (26); wherein the fastener devices (58) are positioned outside the cover plate (40). A battery pack system (20) and an electrified heavy-duty vehicle (10) are also provided.