Bottle-Shaped Battery Pack for Electric Bikes
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Solution Overview
Problem
Existing electric bikes face challenges in accommodating a battery pack that is both moisture-proof and structurally stable, especially when subjected to external impacts during operation.
Innovation Solution
A battery pack designed in a bottle shape with a protecting circuit module and connection terminals, integrated with a bike frame that includes a bottle cage for secure mounting and protection from moisture, utilizing a multi-stage battery array connected in series and parallel configurations for efficient power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery pack is designed with exposed electrical connection terminals for easy charging, then the ease of operation is improved, but the reliability deteriorates due to moisture ingress
Solution Approach 1:
A waterproof cap is introduced as an intermediary component between the electrical connection terminals and the external environment. The cap includes a receiving space that accommodates the terminals and a waterproof layer that prevents moisture ingress while allowing electrical connection when the charging device is coupled to the battery pack
Solution Approach 2:
The battery pack is divided into functionally independent modules: a battery module containing batteries, a protection circuit module, a connection terminal section with terminals, and a waterproof cap. This segmentation allows the electrical connection terminals to be accessible for charging while the waterproof cap protects them from moisture when not in use
2Volume of moving object
If the battery pack uses a compact bottle shape for easy mounting, then the volume is reduced, but the stability deteriorates under external impact
Solution Approach 1:
Shock-absorbing sponges are pre-installed between the battery module and the battery pack housing, and between the protection circuit module and the housing. These sponges provide beforehand cushioning that absorbs external impacts and prevents damage to internal components while maintaining the compact bottle shape
Solution Approach 2:
The battery pack combines different materials with complementary properties: a metal or rigid housing for structural strength, shock-absorbing sponges for impact protection, and a waterproof cap with waterproof layer for moisture protection. This composite material approach achieves both compact size and structural stability
3Device complexity
If the battery pack integrates all components in a compact design, then the device complexity is reduced, but the reliability deteriorates due to lack of protection for individual components
Solution Approach 1:
The battery pack is segmented into distinct functional modules: battery module, protection circuit module, connection terminal section, and waterproof cap. Each module is independently protected - batteries are cushioned from shocks, the protection circuit module has dedicated shock-absorbing sponges, and the connection terminals are protected from moisture by the waterproof cap
Solution Approach 2:
The design employs a nested structure where the battery module and protection circuit module are housed within the battery pack housing, the connection terminals are received within the waterproof cap, and shock-absorbing sponges are positioned between components and the housing. This nesting provides integrated protection while maintaining compact integration
Data Source
AI summary
Provided is an food packing material, manufacturing method. A battery pack and a electrical bike having the same are further provided. In particular, the battery pack may include a battery pack, battery array, a protecting circuit module, and a connection terminal section. The battery case may be formed as cylindrical or polygon. The battery array may include a plurality of batteries formed as multi-stage within the battery pack. The protecting circuit module may be provided between an upper portion of the battery array and an upper surface of the battery pack. A connection terminal portion may be formed at the lower stage of the battery pack and may include a power terminal and a control terminal. By providing the battery pack as bottle shape, the electrical bike can selectively accommodate the bottle for the bike and the battery pack.