Battery Pack Spacer Design for Non-Destructive Disassembly
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Solution Overview
Problem
Conventional battery packs are difficult to restore due to the challenge of removing the cover from the tray without damaging either component, which prevents effective reuse of the battery pack.
Innovation Solution
A battery pack design featuring a connection member with a spacer having varying cross-sectional areas, guiding a saw to cut the sealant and spacer without contacting the tray or cover, allowing for safe disassembly and reassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover and tray are joined tightly to prevent moisture entry, then sealing performance is improved, but the difficulty of disassembly increases and the cover cannot be reused
Solution Approach 1:
The connection member is divided into three portions with different cross-sectional areas: a first portion contacting the tray, a second portion with smaller cross-sectional area for saw insertion, and a third portion contacting the cover. This segmentation allows the disassembly tool to access the joint through the narrower second portion while the wider first and third portions maintain secure contact with the tray and cover, enabling disassembly without damaging the cover or tray.
2Ease of repair
If the cover is removed from the tray for component replacement, then restoration is enabled, but the cover may be damaged during removal
Solution Approach 1:
The connection member acts as an intermediary element between the tray and cover. Its second portion with smaller cross-sectional area serves as an access channel for the saw blade, allowing the disassembly tool to reach and cut the sealant without the saw blade contacting and damaging the cover or tray. The first and third portions with larger cross-sectional areas maintain structural contact with the tray and cover respectively, providing support during the disassembly process.
3Ease of operation
If a saw is inserted to cut the sealant and spacer, then disassembly is enabled, but the tray or cover may be damaged by saw contact
Solution Approach 1:
The connection member exhibits local quality variation through its three portions with different cross-sectional areas. The second portion has a locally reduced cross-sectional area that creates a safe passage for the saw blade, while the first and third portions maintain larger cross-sectional areas to provide structural support and contact with the tray and cover. This local quality differentiation enables the saw to cut the sealant and spacer without contacting and damaging the tray or cover.
Data Source
AI summary
A battery pack may include a tray, a cover, a connection member connecting a peripheral portion of the tray to a peripheral portion of the cover with a clearance provided therebetween, and a sealant filling the clearance. The connection member may include a spacer disposed in a range between the peripheral portion of the tray and the peripheral portion of the cover. The spacer may include first to third portions respectively having first to third cross-sectional areas. The second cross-sectional area may be smaller than the first and third cross-sectional areas. The first portion may be disposed at a position that is in contact with the peripheral portion of the tray. The third portion may be disposed at a position that is in contact with the peripheral portion of the cover. The second portion may be disposed between the first portion and the third portion.