Waterproof Battery Pack Assembly via Segmented Welded Opening
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Solution Overview
Problem
The existing manufacturing methods for battery packs face challenges in maintaining a waterproof structure during assembly, as the battery core pack tends to protrude or not stay inside the waterproof bag, delaying the process and making it difficult to achieve an ideal waterproof assembly.
Innovation Solution
A manufacturing method involving a flexible waterproof bag with a smaller inserting opening created by welding, allowing the battery core pack to be inserted in a changed direction, followed by injecting potting resin and bending the bag to secure the lead wire, ensuring the battery core pack remains inside and maintaining a waterproof seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the battery core pack is inserted through a large opening portion of the waterproof bag, then the insertion process is easy and fast, but the battery core pack cannot be prevented from protruding or falling out during subsequent manufacturing steps
Solution Approach 1:
The opening portion is segmented into two functional zones: a large insertion region for easy battery core pack insertion, and a smaller sealed region for maintaining waterproof integrity. The welding portion divides the opening into an insertion opening (smaller) and a sealed opening (larger), allowing the battery core pack to be inserted easily while preventing it from protruding during subsequent steps.
Solution Approach 2:
Different regions of the opening portion are given different qualities: the insertion opening is made smaller and positioned to control battery core pack movement, while the sealed opening maintains the waterproof barrier. The welding portion creates local structural differences that enable both easy insertion and reliable containment.
2Reliability
If the opening portion is made small to prevent battery core pack protrusion, then the waterproof structure is maintained, but the insertion process becomes difficult and time-consuming
Solution Approach 1:
The opening portion is divided into an insertion opening and a sealed opening. The insertion opening is positioned and sized to allow easy battery core pack insertion, while the sealed opening maintains the waterproof barrier. This segmentation enables both efficient assembly and reliable waterproofing without compromise.
Solution Approach 2:
The welding portion is positioned to create the insertion opening at a location and size that facilitates easy battery core pack insertion before the sealing process. This preliminary configuration of the opening structure enables efficient insertion while maintaining subsequent waterproof integrity.
3Ease of operation
If the waterproof bag is made flexible to accommodate various postures during manufacturing, then the bag can be handled easily, but the battery core pack cannot be kept at a fixed position
Solution Approach 1:
The waterproof bag has different regional properties: the main body remains flexible for easy handling and posture adjustment, while the opening portion has enhanced structural control through the welding portion that prevents battery core pack protrusion. This local structural differentiation maintains both flexibility and position stability.
Solution Approach 2:
The waterproof bag structure is segmented into a flexible main body for handling and a controlled opening portion for position stability. The welding portion creates a structural boundary that maintains battery core pack position while allowing the rest of the bag to remain flexible for manufacturing operations.
4Reliability
If the opening portion is fully sealed to maintain waterproofing, then the waterproof structure is complete, but the battery core pack cannot be inserted
Solution Approach 1:
The opening portion is segmented into an insertion opening and a sealed opening. The insertion opening allows battery core pack insertion while the sealed opening maintains waterproof integrity. The welding portion creates this functional division, enabling both insertion capability and waterproof seal completeness.
Solution Approach 2:
Different regions of the opening portion are given different sealing qualities: the insertion opening remains open for battery core pack insertion, while the sealed opening is closed to maintain waterproofing. This local differentiation of sealing properties enables both insertion and complete waterproofing.
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
This method enables efficient assembly of battery packs with a reliable waterproof structure, preventing the battery core pack from protruding and ensuring a hermetic seal, thus streamlining the manufacturing process and maintaining the integrity of the waterproof design.
Implementation Method 1
welding the flexible sheet 21 facing at the opening portion 20 as a welding portion 22
Data Source
Figure 1
Figure 2
Figure 3
AI summary
This battery pack is assembled by welding an opening portion (20) of a waterproof bag (2) to provide an insertion opening (23) that is smaller than the total opening width (W) but allows a battery core pack (1) to be inserted, inserting the battery core pack (1) into the waterproof bag (2), then, closing the opening portion (20) of the waterproof bag (2), and placing the waterproof bag (2), in which the battery core pack (1) has been placed, into an external case (3). In this way, this battery pack can be assembled efficiently, with the battery core pack having been given a waterproof structure by the waterproof bag (2) while in an ideal state.