Battery Case Insert-Nut Pinhole Blocking for Waterproof Sealing
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Solution Overview
Problem
Lithium secondary battery cases face challenges in achieving high waterproof performance, particularly due to pinholes formed during the manufacturing process which can lead to water leakage.
Innovation Solution
A battery case design that includes an upper and lower case with an insert nut and pinhole, where the pinhole is blocked using a heating member to prevent water ingress, enhancing the waterproofing by forming a sealing portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If injection molding is used to manufacture the battery case with an insert nut, then manufacturing efficiency and cost are improved, but pinholes are formed during the process which compromise waterproof performance
Solution Approach 1:
The pinhole is blocked in advance during the manufacturing process by inserting a blocking member through the insert nut into the pinhole position, preventing water leakage before the product is put into service. This preliminary action resolves the contradiction by maintaining both the manufacturing efficiency of injection molding and the waterproof reliability of the final product.
Solution Approach 2:
The harmful pinhole defect is extracted and addressed by introducing a separate blocking member to seal it, separating the defect remediation from the main injection molding process. This allows the manufacturing process to remain efficient while the waterproof reliability is restored by removing the harmful effect of the pinhole.
2Manufacturing precision
If a pin is used to support the insert nut during manufacturing, then the insert nut positioning is improved, but a pinhole is created that requires additional blocking steps
Solution Approach 1:
The pin serving dual functions: it positions the insert nut during manufacturing and simultaneously serves as the blocking member to seal the pinhole. By merging the positioning function and the sealing function into a single component, the manufacturing precision is maintained while the additional blocking step is eliminated, reducing overall process complexity.
Solution Approach 2:
The pin is designed with multi-functionality: it acts as both a positioning tool during injection molding and as a permanent blocking member to seal the pinhole. This universal component resolves the contradiction by achieving precise insert nut positioning without increasing device complexity, as the same pin performs both functions.
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 blocking of pinholes effectively prevents water leakage, thereby improving the waterproof performance of the battery case, ensuring the integrity of the battery module, pack, and vehicle applications.
Implementation Method 1
a heating member heats the protrusion to seal the pinhole
Data Source
AI summary
Provided are a battery case, a battery module, a battery pack, and a vehicle including the battery case, and a method of manufacturing the battery case. A battery case according to an embodiment includes a lower case in which a plurality of battery cells are accommodated, and an upper case coupled to the lower case, wherein an insert nut is provided in at least one of the upper case and the lower case, a pinhole is formed at a position adjacent to the insert nut of the at least one of the upper case and the lower case, and the pinhole is blocked.