Battery Pack Cover with Stepped Connection and Rounded Boundaries
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Solution Overview
Problem
Existing battery packs face challenges in maintaining structural integrity and preventing stress concentration, which can lead to damage during assembly and operation, especially due to the design of covers that are prone to deformation under external loads or vibrations.
Innovation Solution
The battery pack design incorporates a frame member with a central opening and covers that include a flange portion and main body connected in a stepped manner with an acute angle, featuring round boundaries to prevent stress concentration and a secure assembly using adhesive members and insulating components, ensuring the battery cell is securely positioned and protected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cover is designed with a stepped structure connecting the flange portion and main body, then the assembly simplicity is improved, but the structural integrity may deteriorate due to potential stress concentration at the connecting portion
Solution Approach 1:
The connecting portion between the flange and main body is designed with a curved surface instead of a sharp corner, and the boundary between the connecting portion and main body is rounded. This curvature design distributes stress more evenly and prevents stress concentration, thereby maintaining structural integrity while preserving the stepped assembly structure.
Solution Approach 2:
The boundary between the connecting portion and main body is specifically rounded rather than leaving the entire structure uniform. This localized quality change at the critical stress area enhances structural integrity without compromising the overall stepped design and assembly simplicity.
2Strength
If the boundary between the connecting portion and main body is made round, then the stress concentration is reduced, but the manufacturing precision requirements may increase
Solution Approach 1:
The boundary is designed with a specific radius of curvature (R1 and R2 in the claims) that balances stress distribution benefits with manufacturability. By optimizing this geometric parameter, the design achieves stress concentration reduction while remaining compatible with standard manufacturing capabilities.
3Ease of manufacture
If the flange portion and main body are connected in a stepped manner, then the assembly process is simplified, but the cover may be prone to deformation under external loads or vibrations
Solution Approach 1:
The connecting portion is designed with a curved surface that gently connects the flange and main body, distributing mechanical stresses more evenly throughout the structure. This curvature prevents sharp corners that would act as stress concentration points during vibration or external loading, thereby improving deformation resistance.
Solution Approach 2:
The rounded boundary at the connecting portion creates a localized stress distribution pattern that enhances overall structural stability. This local quality modification prevents deformation propagation while maintaining the global stepped structure for assembly simplicity.
Data Source
AI summary
A battery pack, including a battery cell; and a case having a receiving space for the battery cell, the case including a frame member including an opening formed in a central portion thereof and having an inner surface facing the receiving space and an outer surface opposite the inner surface; a first cover on the frame member, the first cover including a flange portion supported on the inner surface of the frame member, a main body exposed through the opening of the frame member, and a connecting portion connecting the flange portion to the main body in a stepped manner; and a second cover coupled to the frame member, the battery cell being between the second cover and the frame member.