Battery Pack Packaging Structure With Groove-Lapped Flat Stacking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional wooden box packaging for battery packs results in uneven surfaces, making proper placement and stacking difficult, and increases the risk of collisions during transportation, leading to potential accidents such as battery leakage, spontaneous combustion, and explosion.
Innovation Solution
A packaging structure comprising a tray structure with a support portion forming a groove and a cover body, allowing for flat assembly without altering the cover shape, which includes a tray body and a support portion that forms a groove at the periphery, accommodating the battery pack in a cavity and being lapped with the cover body, enhancing stability and preventing collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the outer short side plate of the top cover is lengthened and fixed to load-bearing blocks with wooden screws, then the top cover and tray can be assembled, but the surface of the wooden box becomes uneven, making it difficult to place battery packs properly and unfavorable for stacking
Solution Approach 1:
The invention divides the top cover into a main body and a separate extension plate component. The extension plate is a distinct segment that can be pre-formed and then attached to the main body, allowing the uneven surface issue to be addressed by designing the extension plate geometry rather than modifying the main cover structure. This segmentation enables the extension plate to have a shape that compensates for the unevenness caused by the loading blocks.
Solution Approach 2:
The extension plate is designed with specific local geometry to address the local unevenness problem. The plate extends only where needed (at the outer short side) and can be shaped to match the contour created by the load-bearing blocks, creating a locally adapted solution that restores overall surface flatness without requiring changes to the entire top cover or tray structure.
2Productivity
If the wooden box is used for long-distance transportation on bumpy journeys, then the battery packs can be transported, but the wooden box may rollover, causing collisions between battery packs and the wooden box or ground, resulting in accidents
Solution Approach 1:
The extension plate is designed in advance with built-in positioning features and attachment mechanisms that pre-establish the correct orientation and position of the top cover relative to the tray. This preliminary design ensures that during loading and transportation, the box maintains its intended stable configuration and is less prone to rollover, as the components are pre-configured to work together as a stable unit.
Solution Approach 2:
The extension plate adds a dimensional element to the top cover structure, extending in the direction needed to interface with the load-bearing blocks. This dimensional addition creates a more stable geometric configuration that resists rollover during transportation, effectively using the extra dimension provided by the extension to improve overall structural stability.
3Ease of operation
If the shape of the top cover is adjusted to complete assembly with the tray, then the components can be connected, but the overall surface of the packaging structure becomes uneven, affecting placement and stacking
Solution Approach 1:
By separating the top cover into a main body and an extension plate, the invention allows the extension plate to be specifically shaped for assembly purposes without altering the main body. This segmentation enables the extension plate to provide the necessary geometric features for easy assembly with the tray while the main body retains a shape that contributes to overall surface flatness when assembled.
Solution Approach 2:
The problematic shape-modifying features are extracted from the main top cover body and placed into a separate extension plate component. This extraction allows the main body to maintain its optimal shape for surface flatness, while the extension plate provides the necessary geometric features for assembly, effectively separating the conflicting shape requirements into different components.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A package structure for a battery pack is provided. The package structure for the battery pack includes a tray structure and a cover body, the tray structure includes a tray body and a support portion. At least a part of the support portion protrudes from a periphery of the tray body in a planar extension direction of the tray body. The support portion cooperates with the tray body to form a groove located at the periphery of the tray body. The cover body is arranged on a first side of the tray body. A cavity is formed on a side, facing the tray body, of the cover body. The battery pack is located on the first side of the tray body and is accommodated in the cavity. At least a part of the cover body is lapped with the groove, and the tray body is accommodated in the cavity.