Battery Cell Insulating Frame With 3D Adhesive Flow Channels
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Solution Overview
Problem
Existing battery packs lack effective insulation and secure fixation methods for battery cells, leading to potential electrical hazards and instability during use.
Innovation Solution
A battery pack design incorporating a housing frame and an insulating frame with specific flow channels for adhesive application, ensuring three-dimensional adhesion and insulation between the battery cells and the housing frame, using convex patterns and flow channels to secure the cells in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fixation methods are used without flow channels, then the structure is simpler, but the adhesion strength and stability are insufficient
Solution Approach 1:
The insulating frame is segmented with multiple flow channels (first flow channel, second flow channel, third flow channel) distributed at different locations and orientations. This segmentation allows adhesive to be distributed throughout the structure, creating multiple adhesion points that collectively enhance fixation strength without requiring a monolithic complex structure
Solution Approach 2:
The flow channels extend in multiple dimensions - the first flow channel extends in the longitudinal direction, the second flow channel extends in the width direction, and the third flow channel extends in the height direction. This multi-dimensional arrangement creates three-dimensional adhesion between the insulating frame, housing frame, and battery cells, significantly improving fixation strength compared to single-plane adhesion methods
2Reliability
If insulating frame is added for electrical isolation, then electrical safety is improved, but the device complexity increases
Solution Approach 1:
The insulating frame serves multiple functions simultaneously: it provides electrical insulation between the battery cells and housing frame, acts as a structural support element, and incorporates flow channels for adhesive application to ensure fixation. This multi-functionality reduces the need for separate components, thereby limiting the increase in overall device complexity while achieving electrical safety
Solution Approach 2:
The insulating frame acts as an intermediary component positioned between the battery cells and the housing frame. It provides electrical isolation while still allowing mechanical connection through the flow channels filled with adhesive, thus achieving both electrical safety and structural integrity without requiring completely separate insulation and fixation systems
3Area of stationary object
If multiple flow channels are created for adhesive flow, then the adhesion coverage is improved, but the manufacturing complexity increases
Solution Approach 1:
The flow channels are pre-formed as integral features of the insulating frame structure during frame manufacturing. The convex patterns and stepped portions creating the flow channels are formed simultaneously with the frame itself, rather than requiring separate post-processing steps. This preliminary action reduces manufacturing complexity despite the increased adhesion coverage area
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 provides robust adhesion and insulation, enhancing the stability and safety of the battery pack by ensuring secure fixation and electrical isolation of the battery cells.
Implementation Method 1
an adhesive provided on a bottom surface of the housing frame, the adhesive flowing along the at least one flow channel in response to a pressure applied due to a weight of the at least one battery cell
Implementation Method 2
a convex pattern that protrudes toward the bottom of the at least one battery cell, and at least one flow channel that forms a flow path for an adhesive
Implementation Method 3
an insulating frame provided between the at least one battery cell and the housing frame
Data Source
Figure 1
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AI summary
A battery pack includes a housing frame to accommodate a battery cell; and an insulating frame provided 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 depth direction of the flange portion opposite to the bottom of the battery cell.