Battery Pack Wire Cover Structure Against Pulling Damage
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Solution Overview
Problem
Battery pack communication lines are prone to damage when attached to a predetermined place due to being pulled by peripheral members.
Innovation Solution
A battery pack design that includes a battery, a control member, a communication line connected to the control member, a covering member, and a fastening member that secures the communication line between the covering and fastening members, with the covering member having a larger outer diameter than the portion to be fastened, preventing damage from peripheral contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the communication line is directly connected without additional protective structures, then the device complexity is reduced, but the communication line is vulnerable to damage from pulling and contact with peripheral members
Solution Approach 1:
The patent introduces a covering member as an intermediary protective layer that wraps around the communication line, and a fastening member as a mediator that secures the covering member to the battery pack housing. These intermediary structures protect the communication line from direct contact with peripheral members and pulling forces, thereby resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The covering member is pre-formed with a specific shape that includes a receiving portion and a protruding portion, which are designed in advance to fit with the fastening member. This preliminary preparation of the protective structure allows for efficient assembly and ensures proper protection without requiring complex assembly procedures, thus addressing the contradiction between reliability and device complexity.
2Reliability
If the covering member has a larger outer diameter than the fastening portion, then the communication line is better protected from pulling, but the space required for the covering member increases
Solution Approach 1:
The covering member is designed with non-uniform cross-sectional area, having a larger outer diameter in the receiving portion that accommodates the communication line and a smaller diameter in the fastening portion. This local variation in dimensions provides adequate protection where needed while minimizing the overall volume, thus resolving the contradiction between reliability and volume.
Solution Approach 2:
The covering member is segmented into functionally distinct portions: a receiving portion for protecting the communication line, a fastening portion for securing the assembly, and a protruding portion for engagement. This segmentation allows each portion to be optimized for its specific function, providing effective protection while minimizing the total volume of the covering member.
3Reliability
If the communication line is secured with a fastening member, then the communication line is protected from pulling damage, but the ease of installation is reduced
Solution Approach 1:
The covering member and fastening member are designed to work together as an integrated protective assembly. The covering member includes a protruding portion that fits with the fastening member, combining the protection and fastening functions into a coordinated system that simplifies the overall assembly process while maintaining reliable securing of the communication line.
Solution Approach 2:
The covering member is pre-formed with the protruding portion that is designed to fit with the fastening member, and the fastening member is pre-configured with the corresponding receiving structure. This preliminary preparation of the components allows for straightforward assembly without requiring complex alignment or additional fastening steps, thus resolving the contradiction between reliability and ease of manufacture.
Data Source
AI summary
A battery pack includes a battery, a control member (a control board) that controls the battery, a communication line (an electric wire) conducted to the control board, a covering member that covers the electric wire, and a fastening member that fastens the electric wire with the covering member interposed therebetween. The covering member includes a portion to be fastened surrounded and fastened by the fastening member, and a covering portion (a first covering portion) exposed from the fastening member. The first covering portion has a portion located on a side closer to the control board than the fastening member and having an outer diameter (D1>D2) larger than that of the portion to be fastened before being fastened by the fastening member.