Battery Pack Waterproof Plug for Water Ingress Detection

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Solution Overview

Problem

Energy storage devices are vulnerable to water ingress through openings in battery packs, leading to potential damage and safety hazards.

Innovation Solution

Incorporation of a waterproof plug with an electrical connection member and a water immersion detection unit that generates a signal upon water entry, allowing for real-time detection and prevention of water leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If an opening is provided in the battery pack housing for connection terminal access, then electrical connection is enabled, but water can flow into the battery pack causing damage

Engineering Contradiction:

Improveelectrical connectionVSAvoidwater ingress

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A waterproof plug is introduced as an intermediary component that covers the opening in the battery pack housing. The waterproof plug includes a detection wire that extends into the opening to detect water presence, while the main body seals the opening to prevent water ingress. This mediator enables both electrical connection functionality and water protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces traditional mechanical sealing methods with an electrical detection system. Instead of using complex mechanical seals or flaps that could fail, the invention uses a detection wire connected to a detection unit that provides electrical signals to indicate water presence, enabling a more reliable and simpler sealing approach.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a waterproof plug with detection wire is installed to prevent water ingress, then safety is improved, but device complexity increases

Engineering Contradiction:

ImprovewaterproofingVSAvoidstructure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The waterproof plug is designed to perform multiple functions simultaneously: it seals the opening to prevent water ingress, provides electrical connection through the detection wire, and enables water detection through the same detection wire structure. This multi-functionality reduces the need for separate components and simplifies the overall device structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The detection wire is designed as a flexible, thin element that can extend into the opening while maintaining electrical continuity. This thin-film approach allows the detection function to be integrated into the waterproof plug without adding significant structural complexity or bulk to the device.

Inventive Principle:

Principle #30Flexible shells and thin films

3Object-affected harmful factors

If traditional complex waterproofing structures are used, then water protection is achieved, but production costs increase

Engineering Contradiction:

Improvewater protectionVSAvoidproduction cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The waterproof plug is designed as a separate, modular component that can be manufactured independently and then assembled onto the battery pack housing. The detection wire is also a separate element that can be produced using standard wiring techniques. This segmentation allows each component to be manufactured using simple, cost-effective processes rather than requiring complex integrated manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The detection wire and waterproof plug are designed as simple, inexpensive components that can be easily replaced if needed. The detection wire uses standard electrical wiring materials, and the waterproof plug can be made from common sealing materials, avoiding the need for expensive specialized components.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

Enhances safety and reliability by detecting water ingress, reduces production costs through a simple and cost-effective design, and facilitates communication address encoding.

Implementation Method 1

the electrical parameter is a voltage, a current, or a resistance value of the water immersion detection wire

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Data Source

PatentUS20250337073A1Energy storage device

Publication Date: 2025.10.30 SHENZHEN HELLO TECH ENERGY CO LTD

AI summary

The present disclosure discloses an energy storage device, including a battery pack, a waterproof plug, and a short circuit detection unit. The battery pack includes a housing and a connection terminal. The housing has an opening, and the connection terminal is disposed at the opening. The waterproof plug includes an electrical connection member configured to, in response to the waterproof plug covering the opening, connect to the connection terminal to generate a second signal. The short circuit detection unit is configured to determine, by detecting the second signal, that the battery pack is located at a bottom of the energy storage device.