Battery Pack Gap Pad Assembly for Pouch Cell Heat Protection
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Solution Overview
Problem
Existing battery pack assembly methods face challenges in efficiently integrating gap pads to provide heat and expansion protection for pouch type battery cells, which are prone to temperature fluctuations.
Innovation Solution
A gap pad assembly with predefined bend lines is used to facilitate easy alignment and affixation to the battery cells, ensuring full coverage and stability during temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gap pad is used to provide heat and expansion protection for battery cells, then protection capability is improved, but assembly complexity increases
Solution Approach 1:
The gap pad is divided into multiple sections with predefined bend lines, allowing each section to be independently positioned and affixed to different sides of the battery cell holder. This segmentation enables simpler assembly by breaking down the complex task of wrapping a single large pad into manageable steps of applying smaller sections.
Solution Approach 2:
Predefined bend lines are incorporated into the gap pad during manufacturing, preparing the pad in advance for easy folding and conforming to the battery cell holder geometry. This preliminary preparation eliminates the need for complex on-site shaping and reduces assembly difficulty.
2Reliability
If a gap pad is affixed to all exposed areas of battery cells, then protection coverage is improved, but manufacturing precision requirements increase
Solution Approach 1:
The gap pad is divided into multiple sections that can be independently aligned and affixed to different exposed areas of the battery cells. This segmentation reduces the precision requirement for each individual section compared to affixing a single large pad, as each smaller section has more forgiving alignment tolerances.
Solution Approach 2:
Each section of the gap pad is designed to cover specific local exposed areas of the battery cells, with dimensions and shapes optimized for their respective positions. This local optimization allows each section to be precisely fitted to its target area, improving overall coverage while maintaining reasonable manufacturing precision standards.
Data Source
AI summary
The present disclosure is directed to a battery pack including a battery pack housing and a core pack within the battery pack housing. The core pack may include a cell holder and a plurality of battery cells held in place by the cell holder. The battery pack also includes a gap pad. The gap pad is affixed to the core pack. The gap pad may be positioned between the core pack and the battery pack housing. The gap pad may include a plurality of predefined bend lines to enable the gap pad to be bent or partially folded about the core pack.