Battery Pack Sealed Side Fold Structure Without Connector Interference
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Solution Overview
Problem
Battery pack containers that aim to improve space efficiency by folding sealed regions upwards often compromise seal integrity and cause manufacturing inefficiencies due to interference with connectors.
Innovation Solution
A container design with a sealed region extending from a first side wall and a terrace region from a second side wall, where the sealed corner is formed at an angle to allow the sealed region to be folded upwards without the fold line extending into the terrace region, and the first corner is shaped to maintain seal integrity by extending a threshold distance from the side wall, eliminating interference with connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the sealed region is folded upwards to improve space efficiency, then the space utilization of the container is improved, but the seal integrity is compromised and manufacturing complexity increases due to interference with connectors
Solution Approach 1:
The container is divided into distinct functional regions: a sealed region for folding, a terrace region for connectors, and a body region. The sealed corner region acts as a transition zone between these segments, allowing the sealed region to be folded upwards without compromising the terrace region or connector integrity.
Solution Approach 2:
The sealed corner region is formed at a specific angle (e.g., 45 degrees) to create localized geometric properties that enable the fold line to terminate before entering the terrace region. This local angular modification ensures that the folding action is contained to the sealed region while preserving the integrity of adjacent regions.
2Area of stationary object
If the sealed region is folded upwards to improve space efficiency, then the space utilization is improved, but manufacturing complexity increases due to interference with connectors
Solution Approach 1:
The container is divided into distinct functional regions: a sealed region for folding, a terrace region for connectors, and a body region. The sealed corner region acts as a transition zone between these segments, allowing the sealed region to be folded upwards without compromising the terrace region or connector integrity.
Solution Approach 2:
The sealed corner region is extracted as a distinct geometric feature with a specific angle (e.g., 45 degrees) that separates the fold line from the terrace region. This extraction ensures that the folding operation does not interfere with connector placement, simplifying manufacturing by eliminating interference issues.
3Ease of manufacture
If the container uses a conventional sealed region design, then manufacturing is simpler, but space efficiency is reduced
Solution Approach 1:
The sealed corner region is pre-formed at a specific angle (e.g., 45 degrees) during container fabrication. This preliminary geometric configuration ensures that when the sealed region is folded upwards, the fold line naturally terminates before entering the terrace region, eliminating the need for complex manufacturing adjustments or rework.
Solution Approach 2:
The solution introduces a angular dimension (the sealed corner region angle) to the conventional rectangular container design. This additional geometric parameter enables the folded configuration to achieve three-dimensional space efficiency while maintaining two-dimensional manufacturing simplicity through the predetermined angular feature.
Data Source
AI summary
The disclosed technology relates to a container configured to enclose a battery cell. The container comprises a sealed region extending from a first side wall of the container and a terrace region extending from a second side wall of the container. The sealed region and the terrace region intersect in a sealed corner region located proximate to a first corner of the container. The sealed corner region is formed at an angle such that the sealed region is configured to be folded upwards along a fold line and attached to the first side wall of the container without the fold line extending into the terrace region. The first corner of the container is shaped such that the sealed region extends at least a threshold distance from the first side wall along an entire length of the sealed region.