Battery Case with Integrated Pouch Support and Terminal Structure
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Solution Overview
Problem
Conventional methods for layering and connecting lithium polymer pouches in high-power batteries are prone to instability and environmental susceptibility, lacking a robust structure to securely connect multiple pouches in series without additional support or connecting devices.
Innovation Solution
A battery case design featuring a main frame and cover frame with integrated pouch support and terminal support structures, allowing flexible lithium unit cells to be layered and connected in series without additional connecting devices, using bent terminals for secure series connections and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to layer and connect lithium polymer pouches, then the battery can be assembled, but the structure is unstable and susceptible to environmental variations
Solution Approach 1:
The case integrates both support and connection functions into a single unified structure. The case body directly holds the pouches through integrated support ribs while simultaneously providing connection terminals, eliminating the need for separate support devices and connecting components. This merging of functions achieves stable pouch connection without increasing device complexity.
Solution Approach 2:
The case is designed as a multi-functional component that simultaneously performs multiple roles: mechanical support for pouches, electrical connection through integrated terminals, and structural protection. The support ribs provide both mechanical stabilization and positioning, while the terminal structure provides both connection and structural integrity, achieving universal functionality that improves reliability without adding complexity.
2Reliability
If additional support devices and connecting devices are used to secure pouches, then connection stability improves, but device complexity and assembly difficulty increase
Solution Approach 1:
The case combines support structures and connection terminals into a single integrated component that is formed as one piece. The support ribs and terminal structures are built-in features of the case itself, eliminating the need for separate assembly steps to attach support devices or connecting components. This integration maintains secure pouch connection while dramatically simplifying the assembly process.
Solution Approach 2:
The case is pre-designed with built-in support ribs and terminal structures that are already in their final positions and configurations before pouch installation. The support features are pre-formed as integral parts of the case structure, eliminating the need for additional assembly operations to install support devices or make connections, thereby simplifying manufacturing while ensuring secure connection.
3Volume of moving object
If a compact case structure is used to reduce volume, then space efficiency improves, but heat dissipation capability may be compromised
Solution Approach 1:
The case employs local quality optimization by providing enhanced thermal management features specifically in areas where heat generation is highest. The terminal structures and support ribs are designed with increased surface area and improved thermal conductivity in localized regions to facilitate heat dissipation from critical areas, while maintaining overall compact case dimensions. This targeted approach addresses heat dissipation needs without compromising volume efficiency.
Data Source
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AI summary
Disclosed herein is a case which protects a plurality of flexible lithium polymer unit cells, has a compact structure to reduce volume, has a simple assembly process, and minimizes heat generated during a high-power charging or discharging operation. The battery case includes a pouch support frame to support a pouch of a unit cell having the pouch and electrode terminals. A heat radiating part having the shape of a shelf is provided on a surface of the pouch support frame, and defines a space for dispersing heat generated from the pouch. A terminal support having the shape of a wall is provided on an edge of the heat radiating part, thus supporting the electrode terminals of the unit cell.