Overmolded Battery Pack Circuit Board Mounting Against Moisture Ingress
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Solution Overview
Problem
Existing methods for securing components within traction battery packs are inefficient and prone to debris and moisture ingress, requiring complex assembly processes and additional fasteners.
Innovation Solution
The use of an overmolded covering to secure a circuit board within a frame, which is injected over the circuit board at low pressure, providing a secure and moisture-resistant encapsulation without the need for separate fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fastening methods are used to secure the circuit board, then the assembly process requires multiple fasteners and complex steps, but this increases assembly time and complexity
Solution Approach 1:
The patent merges the circuit board securing function with the frame structure by integrating the circuit board directly into the frame body, eliminating the need for separate fasteners and reducing assembly steps to a single injection molding operation
Solution Approach 2:
The frame is designed to serve multiple functions: it provides structural support, houses the circuit board, and integrates the circuit board securing function all in one component, reducing the need for additional fastening parts
2Reliability
If traditional fastening methods are used to secure the circuit board, then separate fasteners are required, but this allows debris and moisture to ingress at fastener locations
Solution Approach 1:
The patent uses a continuous frame structure that fully encloses the circuit board, creating a sealed environment that prevents debris and moisture ingress while eliminating gaps at fastener locations
Solution Approach 2:
By merging the circuit board securing function with the frame structure itself, the patent eliminates separate fasteners that would create potential ingress paths, achieving both simplified assembly and improved environmental protection
3Strength
If multiple fasteners are used to secure the circuit board, then the assembly process becomes more complex, but this provides secure mounting
Solution Approach 1:
The patent merges the circuit board mounting function with the frame structure by integrating the circuit board directly into the frame body through injection molding, providing secure mounting without requiring multiple separate fasteners
Solution Approach 2:
The patent replaces the mechanical fastening system with an injection molding process that integrates the circuit board into the frame, achieving secure mounting through material bonding rather than mechanical fasteners
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
Reduces assembly time and complexity while enhancing protection against debris and moisture, ensuring reliable electrical connections and monitoring capabilities.
Implementation Method 1
an overmolded covering that secures the circuit board to the frame
Implementation Method 2
the overmolded covering is an low-pressure overmolded covering
Data Source
AI summary
A traction battery pack assembly includes a frame; one or more busbars secured to the frame; a circuit board; and an overmolded covering that secures the circuit board to the frame. A traction battery pack circuit board securing method includes positioning a circuit board adjacent a frame. The frame is configured to hold a plurality of busbars of a traction battery pack. The method further includes overmolding the circuit board with a covering to secure the circuit board relative to the frame.