Battery Pack Holder Structure for Stronger Cell Adhesive Fixation
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Solution Overview
Problem
Existing battery packs face challenges in securely fixing secondary battery cells due to reduced adhesive application areas, leading to insufficient bonding strength and potential rotation or disconnection under external forces like vibration.
Innovation Solution
A battery pack design with a battery holder divided into multiple subholders, featuring push ribs and cutouts that guide adhesive to wider gaps, ensuring secure fixation and increased bonding strength by allowing uncured adhesive to spread more effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery holder is divided into multiple subholders to accommodate secondary battery cells, then the structural organization and accessibility are improved, but the adhesive application area is reduced leading to insufficient bonding strength
Solution Approach 1:
The battery holder is divided into multiple subholders (first subholder, second subholder, third subholder) that are stacked in the vertical direction. Each subholder accommodates specific portions of the battery cells, allowing organized separation while maintaining overall structural integrity and adhesive bonding strength through continuous adhesive application across all subholder interfaces.
Solution Approach 2:
The solution transitions from a single-plane adhesive application to multi-level adhesive bonding across vertically stacked subholders. The adhesive is applied to multiple surfaces including the first and second surfaces of each subholder, effectively utilizing the vertical dimension to increase total adhesive bonding area while maintaining compact horizontal footprint.
2Ease of manufacture
If adhesive is applied only to exposed portions of battery cells, then the manufacturing process is simplified, but the bonding strength is insufficient to prevent rotation and displacement under vibration
Solution Approach 1:
Uncured adhesive is applied in advance to multiple surfaces of the subholders (first and second surfaces of each subholder) before the battery cells are fully assembled. This preliminary adhesive application ensures that when the structure is completed and cured, the battery cells are securely bonded along their entire length, preventing rotation and displacement under vibration.
Solution Approach 2:
The adhesive application is made continuous across all interfaces between subholders and battery cells. The uncured adhesive is applied to the first surface of the first subholder, second surface of the first subholder, first surface of the second subholder, and second surface of the second subholder, creating continuous bonding zones that ensure reliable fixation throughout the entire assembly.
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 bonding strength by facilitating adhesive application to deeper and wider gaps, preventing rotation and disconnection of secondary battery cells, even under external forces.
Implementation Method 1
adhesive layers continuously extending through first gaps and second gaps... bonding strength... preventing rotation and displacement
Data Source
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AI summary
Secondary battery cells can be fixed securely. A second holder 20 has rib receiving spaces 44 surrounding peripheries of push ribs 14. The rib receiving spaces 44 are defined by second partitions 22 and exterior cans of secondary battery cells 1. Adhesive layers 50 continuously extend through first gaps GP1 and second gaps GP2. Each first gap GP1 is defined between a periphery of the corresponding push rib 14 placed in the corresponding rib receiving space 44 and the exterior cans of adjacent secondary battery cells 1. Each second gap GP2 extends in a length direction of the secondary battery cells 1 between an inner surface of the corresponding second cylinder 21 and the exterior cans of the adjacent secondary battery cells 1. The inner surface is continuous from an end of a cutout bottom surface 25. Each second gap GP2 is defined in parts of the second cylinders 21 in a circumferential direction intersecting with the length direction. The first gaps GP1 have a first cross-sectional area S1 smaller than a second cross-sectional area S2 of the second gaps GP2 in a direction in which the rib receiving spaces 44 extend. The first cross-sectional area S1 is an area taken along a first plane intersecting with a direction in which the push ribs 14 protrude. The second cross-sectional area S2 is an area taken along a second plane intersecting with the direction in which the push ribs 14 protrude.