Mechanical construction
Enclosures
Battery pack enclosures are usually fabricated in either a thermo-plastic or of a metallic material.
In either case, EAC utilizes 3D solid modeling to design and develop such enclosures. During the design phase, the following parameters must be considered.
- Venting
- Cooling
- Impact strength
- Drop Test Requirements
- Mechanical Clearances
- Regulation Requirements
- Available area vs. maximum dimension of internal components
- Bonding methods:
- Ultrasonic
- Adhesive Bonding
- Mechanical by way of hardware
Prior to fabrication of tooling, EAC utilizes SLA models to verify the 3D design.
Safety
When a battery pack is designed, the absolute first parameter that is taken into consideration is the Safety of the pack.
The parameters which would be considered are as follows:
- Potentials for mechanical short circuits.
- Routing of wire leads
- Routing of connecting straps
- Insulation
- Adhesives
- Strategic placements of safety components
