Low-Rigidity Insulation Part for Battery Stress Mitigation

Solution Overview

Problem

Secondary batteries embedded in rigid insulation layers, such as epoxy resin, face damage due to stress from volume changes during charging and discharging, as the stress cannot be released effectively.

Innovation Solution

A battery built-in board design featuring a secondary battery covered by a low-rigidity insulation part, which allows stress release and improves production efficiency by using a low-rigidity silicone resin for the insulation part, reducing the risk of damage from volume changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a secondary battery is embedded in a rigid insulation layer (e.g., epoxy resin), then the insulation layer provides structural support and electrical insulation, but the stress due to volume change of the battery during charging and discharging cannot be released, leading to potential battery damage

Engineering Contradiction:

Improvestructural supportVSAvoidbattery damage resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies local quality by using different insulation materials with different rigidities in different regions. Specifically, a first insulation layer with relatively high rigidity (e.g., epoxy resin) provides structural support, while a second insulation layer with low rigidity (e.g., silicone resin) is formed on the battery surface to allow volume change. This local differentiation resolves the contradiction between needing structural support and allowing stress release.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining two different insulation materials with complementary properties. The first insulation layer (high rigidity) and second insulation layer (low rigidity) work together as a composite structure, where each material contributes its advantageous property to solve the overall problem of both structural support and stress accommodation.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If a secondary battery is embedded in a rigid insulation layer, then the insulation layer maintains its shape and provides mechanical strength, but the battery may be damaged due to inability to release stress from volume changes

Engineering Contradiction:

Improveinsulation layer stabilityVSAvoidbattery component reliability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent applies local quality by using different insulation materials with different rigidities in different regions. Specifically, a first insulation layer with relatively high rigidity (e.g., epoxy resin) provides structural support, while a second insulation layer with low rigidity (e.g., silicone resin) is formed on the battery surface to allow volume change. This local differentiation resolves the contradiction between needing structural support and allowing stress release.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining two different insulation materials with complementary properties. The first insulation layer (high rigidity) and second insulation layer (low rigidity) work together as a composite structure, where each material contributes its advantageous property to solve the overall problem of both structural support and stress accommodation.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If the battery is mounted directly on the wiring board without a low-rigidity insulation part, then the manufacturing process is simpler, but the battery component cannot withstand stress from volume changes during charging and discharging

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidbattery damage resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies parameter changes by modifying the rigidity parameter of the insulation material that contacts the battery. The second insulation layer uses a material with low rigidity (silicone resin) compared to conventional insulation materials, allowing the battery to expand and contract during charging and discharging without damage.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10249859B2Battery built-in board and method for manufacturing the same

Publication Date: 2019.04.02 SHINKO ELECTRIC IND CO LTD

AI summary

A battery built-in board includes a battery component comprising a battery and an insulation part covering the battery, a first insulation layer in which the battery component is placed, and a second insulation layer formed on the first insulation layer and covering the battery component. Rigidity of the insulation part is lower than that of the first insulation layer and the second insulation layer.