Battery Cell Insulating Frame for 3D Adhesive Fixation
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Solution Overview
Problem
Existing battery packs lack a robust and efficient mechanism for securely fixing battery cells within the housing frame, leading to potential instability and reduced adhesion, which can affect the performance and longevity of the battery pack.
Innovation Solution
A battery pack design incorporating an insulating frame with a convex pattern and flow channels that allows adhesive to flow and fill specific regions, providing three-dimensional adhesion between the battery cells, housing frame, and insulating frame, ensuring secure fixation of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery pack designs are used without specialized insulating frames and flow channels, then the device complexity is lower, but the adhesion strength and stability of battery cells within the housing frame are insufficient
Solution Approach 1:
An insulating frame is introduced as an intermediary component between the housing frame and battery cells. This frame includes a flange portion with flow channels that mediate the adhesive bonding process, enabling strong adhesion while maintaining electrical insulation and structural organization.
Solution Approach 2:
The insulating frame extends in multiple dimensions: the flange portion extends horizontally to define flow channels for adhesive distribution, while the side portion extends vertically to contact side surfaces of battery cells. This multi-dimensional structure enhances adhesion strength beyond simple planar contact.
2Reliability
If adhesive is applied without controlled flow paths, then the manufacturing process is simpler, but the adhesive distribution is uneven and adhesion reliability is reduced
Solution Approach 1:
The adhesive application area is segmented into multiple flow channels formed in the flange portion of the insulating frame. These channels divide and direct adhesive flow to specific regions, ensuring uniform distribution across the bonding surface and improving adhesion reliability.
Solution Approach 2:
The flow channels are pre-formed in the insulating frame structure before adhesive application. This preliminary configuration of flow paths guides adhesive distribution automatically during assembly, eliminating the need for complex external adhesive application equipment or processes.
3Stability of the object's composition
If battery cells are fixed without three-dimensional adhesion structure, then the device complexity is lower, but the stability and prevention of cell movement is insufficient
Solution Approach 1:
The insulating frame provides three-dimensional fixation: the flange portion bonds battery cell bottoms to the housing frame in the horizontal plane, while the side portion extends vertically to bond side surfaces of battery cells. This multi-directional adhesion prevents cell movement in multiple directions, enhancing stability.
Solution Approach 2:
The insulating frame with its flange and side portions creates a nested fixation structure where the frame is positioned within the housing frame, and battery cells are positioned within the insulating frame structure. This nested arrangement provides stable fixation through multiple contact surfaces.
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 enhances the adhesion between the battery cells and the housing frame, providing a stable and secure assembly that prevents movement and ensures reliable performance and longevity of the battery pack.
Implementation Method 1
an adhesive on the bottom of the housing frame may be flowable along the at least one flow channel in response to a pressure applied due to a weight of the at least one battery cell
Data Source
AI summary
A battery pack includes a housing frame to accommodate a battery cell; and an insulating frame between the battery cell and the housing frame, and including an opening through which a bottom of the battery cell is exposed to a bottom of the housing frame, a flange portion that extends along a periphery of the opening, defines the opening, and faces the bottom of the battery cell, and a side portion that is bent from the flange portion and faces a side surface of the battery cell, wherein the flange portion of the insulating frame includes a convex pattern that protrudes toward the bottom of the battery cell, and a flow channel that forms a flow path for an adhesive, the flow channel being a stepped portion stepped down from the convex pattern in a vertical direction opposite to the bottom of the battery cell.