Battery Pack Wire Sealing Using Elastic Compression Bands
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Solution Overview
Problem
Existing methods for sealing wires in battery packs, particularly those using resin, face challenges in maintaining a waterproof seal due to the weakening of adhesive strength during resin hardening, leading to potential seal failure.
Innovation Solution
A wire sealing apparatus using a band part with elastic members and a clamping part to securely seal wires without resin, utilizing elastic members with a compression ratio of 50% to 90% and materials like high-density polyurethane foam or rubber, ensuring a strong and flexible seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin is used to seal wires in battery packs, then the sealing process is simplified, but the adhesive strength weakens during resin hardening leading to potential seal failure
Solution Approach 1:
The patent replaces the chemical bonding mechanism of resin with a mechanical compression system consisting of elastic members and a compression ring. The elastic members compress the wires mechanically against the compression ring, eliminating the need for resin adhesion and its associated hardening strength issues.
Solution Approach 2:
The patent changes the sealing mechanism from chemical bonding (resin) to mechanical compression (elastic members with compression ratio of 50-90%). This parameter change in the sealing approach maintains reliability while preserving manufacturing simplicity.
2Reliability
If elastic members with high compression ratio (50% to 90%) are used, then seal integrity is improved, but material selection and compression control become more critical
Solution Approach 1:
The patent specifies a compression ratio range of 50% to 90% for the elastic members, optimizing the balance between seal integrity and material feasibility. This parameter specification ensures sufficient compression force while remaining within the capabilities of available elastic materials like rubber or polyurethane foam.
Solution Approach 2:
The patent applies different material properties to different components: the elastic members use materials with specific compression ratios (50-90%), while the compression ring provides rigid structural support. This local differentiation of material qualities optimizes the overall sealing performance.
3Reliability
If a band part with multiple elastic members is used to seal wires, then sealing reliability is improved, but the structure becomes more complex compared to simple resin application
Solution Approach 1:
The patent divides the sealing function into segmented components: multiple elastic members distributed along the band part, each compressing individual wires or wire groups. This segmentation allows reliable sealing of multiple wires while maintaining a modular, manageable structure.
Solution Approach 2:
The patent merges the elastic members with the band part structure, integrating the sealing function into the existing band assembly. This merging reduces overall system complexity by combining multiple functions (support, compression, sealing) into a unified structure.
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 apparatus provides a robust waterproof seal by filling the wire's curved surface with soft elastic members and applying external clamping force, maintaining seal integrity and simplifying the sealing process without the need for resin.
Implementation Method 1
the elastic member may be made of a material having a compression ratio of 50% to 90%
Data Source
AI summary
Disclosed are a wire sealing apparatus, a waterproof battery pack, and a method of manufacturing the waterproof battery pack. The wire sealing apparatus may be a wire sealing apparatus for surrounding a battery core pack with a waterproof material and sealing wires of the battery core pack, and may include a band part that extends in a length direction thereof, a plurality of elastic members provided at intervals of one or more elastic members in the length direction of the band part, and a clamping part configured to seat a plurality of wires interposed in a waterproof material in an interval between the plurality of elastic members and to clamp the band part so that the band part surrounds and seals the plurality of elastic members, the waterproof material, and the plurality of wires.