Rechargeable Battery Pack Terminal Sealing and Disassembly
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Solution Overview
Problem
Existing rechargeable battery packs for vehicles are difficult to disassemble for repair and lack effective waterproofing, making maintenance and repair challenging.
Innovation Solution
A rechargeable battery pack design featuring a tab and terminal system where the tab is drawn out of the upper case, bent on its surface, and the terminal is electrically connected to it, covering the through-hole for water resistance, with a disassembly structure that includes hooks and grooves for easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to seal the battery pack, then waterproof performance is improved, but disassembly difficulty increases
Solution Approach 1:
The battery pack is divided into separate components (upper case, lower case, terminal assembly) that can be easily assembled and disassembled. The terminal assembly with integrated gasket can be detached and reattached multiple times without compromising waterproof integrity, enabling easy repair while maintaining sealing performance.
Solution Approach 2:
A gasket is introduced as an intermediary sealing element between the upper and lower cases. This gasket provides the waterproof function that previously required ultrasonic welding, while allowing the cases to be easily separated and reassembled. The gasket acts as a mediator that enables both waterproofing and ease of disassembly.
2Reliability
If the tab is drawn out through a through-hole for electrical connection, then electrical connectivity is improved, but water resistance deteriorates
Solution Approach 1:
The terminal assembly merges the electrical connection function with the waterproof sealing function into a single integrated component. The terminal makes surface contact with the tab for electrical connectivity, while simultaneously covering and sealing the through-hole to prevent moisture ingress, eliminating the need to choose between electrical access and water resistance.
Solution Approach 2:
The terminal assembly serves multiple functions simultaneously: it provides electrical connection to the tab, seals the through-hole to prevent water penetration, and acts as a mounting structure. This multi-functional design resolves the contradiction by making a single component that achieves both electrical connectivity and water resistance.
3Reliability
If the terminal covers the through-hole for water resistance, then waterproof performance is improved, but electrical connection complexity increases
Solution Approach 1:
The terminal assembly combines the sealing function and electrical connection function into a single integrated component rather than using separate elements. This merger simplifies the overall structure by eliminating the need for additional seals or grommets, reducing component count while achieving both waterproofing and electrical connectivity.
Data Source
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AI summary
The present invention has been made in an effort to provide a rechargeable battery pack that is capable of allowing easy disassembly during repair work and waterproof performance in operation. A rechargeable battery pack according to an exemplary embodiment of the present invention includes: a cell holder for accommodating unit battery cells; a lower case for accommodating the cell holder; an upper case combined with an opening of the lower case to cover the cell holder and the unit battery cells; a tab with its end portion drawn out of a through-hole of the upper case so as to be disposed on an outer surface of the upper case while connecting the unit battery cells; and a terminal electrically connected the end portion of the tab while being overlapping therewith and combined with the upper case while covering the through-hole.