The structural design of the protective housing
main content
The motorcycle starting lithium battery needs to withstand up to 15G mechanical impact and IP67 waterproof and dustproof requirements under complex road conditions. The structural design of the protective shell directly determines the safety and reliability of the battery pack.
the mechanical innovation of buffer design
1. Multilevel energy dissipation system
The lithium battery shell realizes the stepwise attenuation of impact force through the bionic structure:
The first stage of buffer: the honeycomb support structure is adopted, and the hexagonal element dispersions the local pressure from 3MPa to 0.7MPa, and the energy absorption efficiency reaches 85%.
Second stage buffer: the core gap is filled with elastic silicone foam (shore hardness 10HA), compression rebound rate ≥95%, can absorb 0.3-0.5mm displacement.
Third level buffer: arc plate and spring expansion rod combination structure, through the slider in the slider displacement (±2mm) with the second/third reset spring, the axial impact into lateral energy dissipation.
2. Mechanical optimization of materials
Gradient modulus design: the outer layer of the shell is made of carbon fiber reinforced epoxy resin (elastic modulus 120GPa), and the inner layer is made of silica gel foam (elastic modulus 0.05MPa) to achieve broadband vibration attenuation of 20-2000Hz.
Fatigue resistance: The hollow-out weight reduction structure optimized by Finite Element Analysis (FEA) maintains 95% structural integrity after 100,000 impact tests.
Fluid dynamics of sealing design
1. Waterproof structure innovation
Ultrasonic welding process: The upper and lower shell adopts 0.5mm triangular fuse line design, through 20kHz high-frequency vibration to make PC material instantaneous melting, forming seamless joint, reaching IP67 protection level.
Multi-channel sealing system:
Main sealing layer: silicone sealing ring (compression rate 15%-20%) embedded in the groove of the shell, contact pressure ≥0.3MPa;
Auxiliary sealing: the edge of the shell is coated with polyurethane sealant, and the elastic waterproof layer is formed after curing.
Emergency pressure relief: integrated one-way ventilation valve (burst pressure 50kPa), balance the internal and external pressure difference to prevent shell cracking.
2. Dustproof and airtight protection
Labyrinth airway design: Z-shaped baffling passage is set at the heat dissipation hole, and the dust settling efficiency is improved by 70% through aerodynamic effect;
Negative pressure detection technology: Helium mass spectrometer leak detector (sensitivity of 1×10⁻ ⁶ Pa·m³/s) was used to ensure that the leakage rate of the shell was < 5×10⁻⁶ mbar·L/s.
Conclusion
The buffer and seal design of the protective shell of the motorcycle starting lithium battery reflects the deep intersection of mechanics, material science and fluid dynamics.
START-STOP LITHIUM battery
Enov start-stop battery is designed to provide excellent performance for high-demand start-stop vaehicles. It adopts the third-generation intelligent lithium platform architecture to achieve technological breakthroughs in core indicators such as cycle life, environmental adaptability and energy density. Compared with the traditional lead-acid battery system, the energy efficiency is increased by 210%, the cycle life is extended by 8-10 times, and the monthly self-discharge rate is controlled within 3%. Enov's unique low-temperature battery technology makes a breakthrough in achieving stable output in the whole climate domain from -30℃ to 65℃, maintaining more than 90% of the effective capacity release under extremely cold conditions (-30℃), and maintaining 90% of the capacity in high temperature environments (65℃).
The start-stop battery series products cover the mainstream voltage platform of 12V/24V/48V, and support flexible configuration of LFP (lithium iron phosphate) and NCM (lithium nickel cobalt manganese oxide) dual-material system. All models adopt modular design to support customization of different model specifications. Enuo engineering and technical team to provide full cycle technical service support, if you need, please contact us.
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