Waterproof Heat-Dissipating Battery Case Design
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Solution Overview
Problem
Conventional battery packs face issues with water penetration and heat dissipation, particularly in outdoor use, leading to potential short circuits and reduced efficiency due to inadequate sealing and heat discharge mechanisms.
Innovation Solution
A waterproof and heat-dissipating battery pack design featuring a flexible case made from fibrous materials like polyamide or polytetrafluoroethylene, with a waterproof structure that includes a bonding portion for the wiring and a sealing portion to prevent water ingress, and an adhesive or thermal fusion method for sealing, allowing effective heat dissipation and improved structural and electrical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional battery pack uses standard sealing methods, then the structure is simple, but water penetration occurs and heat dissipation is insufficient
Solution Approach 1:
The battery pack case is divided into multiple functional layers: a waterproof base layer and a heat-dissipating case layer with heat dissipation fins. This segmentation allows each layer to specialize in its function - the base layer provides waterproofing while the finned layer provides heat dissipation, resolving the contradiction between reliability and structural complexity by creating modular functional zones.
Solution Approach 2:
The case structure combines waterproof materials (such as waterproof adhesive and sealing members) with heat-dissipating structural elements (heat dissipation fins). This composite approach integrates both waterproofing and thermal management functions into a unified case structure, improving reliability without requiring entirely separate systems.
2Ease of operation
If wiring is drawn out of the battery pack, then electrical connection is enabled, but water penetration risk increases at the wiring exit
Solution Approach 1:
The waterproof structure applies localized sealing measures at the wiring exit region rather than requiring complete case disassembly. A sealing member is positioned specifically at the wiring penetration point to maintain waterproof integrity where the wiring exits the case, allowing electrical connection while preserving local waterproof quality.
Solution Approach 2:
A sealing member acts as an intermediary element between the wiring and the waterproof case structure. This sealing member fills the gap created by the wiring penetration and maintains the waterproof barrier, enabling electrical connection through the case while preventing water infiltration at the critical wiring exit point.
3Temperature
If heat dissipation structures are added to the battery pack, then heat dissipation improves, but the waterproof sealing may be compromised
Solution Approach 1:
The case is segmented into a waterproof base layer and a separate heat-dissipating case layer with fins. This segmentation allows the heat dissipation fins to be added without compromising the integrity of the waterproof base layer, as each layer performs its specialized function independently.
Solution Approach 2:
The case structure uses composite construction combining waterproof materials in the base layer with thermally conductive structural elements (heat dissipation fins) in the outer layer. This composite design enables simultaneous achievement of waterproofing and heat dissipation functions without mutual interference.
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 solution effectively prevents water penetration and enhances heat dissipation, improving the performance and stability of the battery pack, ensuring reliable operation in various climates and extending the lifespan of the battery cells.
Implementation Method 1
a waterproof and heat-dissipating case formed of a flexible material and for surrounding the core pack
Implementation Method 2
heat-dissipating case
Implementation Method 3
a bonding portion between the accommodating portion and the cover
Data Source
AI summary
A battery pack including a core pack having a number of battery cells; a waterproof and heat-dissipating case formed of a flexible material that surrounds the core pack; and wiring that is electrically connected to the core pack and is drawn out of the waterproof and heat-dissipating case. A waterproof structure that prevents water penetration is formed in a portion of the waterproof and heat-dissipating case from where the wiring is drawn. Accordingly, water from the outside is effectively prevented from entering the battery pack and heat of the battery cells may be effectively dissipated out of the battery pack.