Waterproof Vehicle Battery Case With Self-Aligning Sealed Frame
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Solution Overview
Problem
Current battery cases for vehicles, such as BEVs and HEVs, fail to adequately protect batteries from water ingress, leading to costly repairs due to leaks through manufacturing gaps and cracks, which can damage the high-value batteries.
Innovation Solution
A waterproof battery case design featuring a frame with extruded case sides and cast case ends, utilizing protrusions to align and seal the sides and ends, and covered by top and bottom covers to prevent water entry, enhancing sealing and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current battery case designs are used, then manufacturing is simpler, but water leakage occurs through gaps and cracks
Solution Approach 1:
The battery case is divided into multiple segments including a frame, front cover, rear cover, and side panels that can be manufactured separately and assembled together. This segmentation allows each component to be optimized for its specific function while maintaining overall waterproofing through precise joining mechanisms.
Solution Approach 2:
Sealing elements such as gaskets and seals are introduced as intermediary components between the frame, covers, and side panels. These intermediaries fill gaps and prevent water leakage at the joints, resolving the contradiction between simpler manufacturing and waterproofing reliability.
2Reliability
If traditional battery case designs are used, then manufacturing cost is lower, but repair cost is high due to battery damage from water leakage
Solution Approach 1:
The case design incorporates pre-installed sealing elements and alignment features during manufacturing that ensure waterproofing is built-in from the start. This preliminary action prevents water leakage before it can damage the battery, maintaining reliability while managing manufacturing complexity through standardized components.
Solution Approach 2:
The design changes the sealing parameters by using swellable protrusions that expand when exposed to moisture, creating a dynamic seal that adapts to environmental conditions. This parameter change enhances battery protection capability without significantly increasing manufacturing complexity.
3Reliability
If protrusions are inserted into cavities to align components, then sealing is improved, but assembly time increases
Solution Approach 1:
The protrusions and cavities are designed with asymmetric geometries that provide self-alignment during assembly. The asymmetric shapes guide the components into the correct position automatically, improving sealing effectiveness while minimizing assembly time by eliminating the need for precise manual alignment.
Solution Approach 2:
The swellable protrusions perform self-service by automatically expanding to fill gaps and create seals once inserted into the cavities. This self-actuating mechanism improves sealing effectiveness without requiring additional assembly steps or tools, thus not increasing assembly time.
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 design improves sealing by eliminating gaps, reduces manufacturing costs, and ensures the battery case remains watertight, protecting the battery from damage while maintaining ease of assembly and reducing the need for extensive tooling.
Implementation Method 1
The plurality of protrusions may be further configured to swell and/or deform the wall to align the plurality of extruded case sides relative to the plurality of cast case ends when the plurality of protrusions are inserted into the one or more cavities
Data Source
AI summary
Systems, devices, and methods for a waterproof case for sealing and protecting a vehicle battery. The case may include a frame formed in the shape of a rectangle and defining a cavity for holding a vehicle battery. The frame may include a plurality of side beams each having one or more cavities having a first width and a first height. The frame may further include a plurality of end beams each having a plurality of protrusions. The plurality of protrusions may each have a greater width than the first width and a greater height than the first height. The plurality of protrusions may be configured to be inserted into the one or more cavities to align the plurality of side beams with the plurality of end beams. The case may further include a plurality of covers configured to sandwich and seal the frame to prevent water from entering the cavity.