Battery Pack Terminal Sealing with Elastic Sheets
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Solution Overview
Problem
Existing battery packs face the risk of electrical short circuits due to conductive substances like water penetrating and adhering to circuit boards, potentially causing permanent damage by connecting terminals improperly.
Innovation Solution
Incorporating elastic sheets around the terminals and between the circuit board and seat surfaces within the battery pack housing to seal and protect connection locations, preventing adverse short circuits and improving adhesion properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the circuit board is mounted directly on the seat surface without sealing, then the structure is simple and easy to manufacture, but conductive substances like water can penetrate and cause short circuits between terminals
Solution Approach 1:
An elastic sheet is introduced as an intermediary component between the circuit board and the seat surface. This sheet surrounds the terminals and creates sealing portions that prevent conductive substances from reaching the connection locations, while still allowing the circuit board to be mounted on the seat surface.
Solution Approach 2:
The elastic sheet functions as a flexible sealing film that conforms to the terminal shapes and creates effective seals around the terminals. The flexibility of the sheet allows it to accommodate the three-dimensional arrangement of terminals while maintaining sealing integrity.
2Reliability
If sealing measures are added to prevent water penetration, then short circuit risk is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The elastic sheet performs multiple functions simultaneously: it provides sealing around the terminals, acts as an insulating barrier, and serves as a mounting interface between the circuit board and seat surface. This multi-functionality reduces the need for additional separate components.
Solution Approach 2:
The solution uses a composite structure combining the rigid circuit board, the flexible elastic sheet, and the seat surface. The elastic sheet material provides both mechanical flexibility for sealing and electrical insulation properties, combining multiple desirable characteristics in a single component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents short circuits between terminals and other conductive materials, ensuring the battery pack's reliability and longevity by isolating potential contact points with conductive substances.
Implementation Method 1
one or more elastic sheets, which surround(s) the perimeter(s) of the terminal(s) and is (are) interposed between the circuit board and the seat surface(s)
Data Source
AI summary
A battery pack includes: a housing (18); one or more battery cells (12) housed inside the housing; one or more seat surfaces (52a, 54a, 56a, 58a) disposed inside the housing; a circuit board (16), which is housed inside the housing and is mounted on the seat surface(s); and one or more terminals (20b, 22b) electrically connected to the circuit board. One or more elastic sheets (60, 62) surround(s) the perimeter(s) of the terminal(s) and is (are) interposed between the circuit board and the seat surface(s).