Battery Cell Junction Tapes for Swelling and Drop Impact
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Solution Overview
Problem
Existing battery packs face issues with reliability and compactness due to swelling and impact from drops, particularly when multiple cells are stacked, leading to potential interference and increased volume.
Innovation Solution
A battery pack design featuring a first tape, stiffer than a second tape, with a gap between them to absorb impact, and a compressible second tape to absorb swelling, along with a layered structure of harder and softer materials to manage cell swelling and impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are stacked to increase output and capacity, then the battery pack can provide higher output voltage and current, but the battery pack becomes more susceptible to damage from drops and swelling
Solution Approach 1:
The patent applies beforehand cushioning by placing shock-absorbing tapes and swelling-absorbing sponges between battery cells before assembly. These protective elements are pre-positioned to cushion against future impacts and swelling, preventing damage when drops or expansion occur during battery operation
Solution Approach 2:
The patent uses intermediary elements (tapes and sponges) placed between battery cells to mediate the interaction during drops or swelling. These intermediaries absorb the harmful effects of impact and expansion, protecting the battery cells from direct damage while allowing the multi-cell configuration to maintain high power output
2Reliability
If protective elements are added between battery cells to absorb swelling and impact, then reliability improves, but the battery pack volume increases
Solution Approach 1:
The patent employs thin film structures (tapes with thickness of 0.1mm or less) as protective elements between battery cells. These flexible thin films provide shock and swelling absorption functionality while occupying minimal space, thus improving reliability without significantly increasing the overall battery pack volume
Solution Approach 2:
The patent optimizes the thickness parameters of protective elements to achieve the desired balance. By controlling the thickness of tapes (0.1mm or less) and sponges (1mm or less), the design maintains adequate protection against drops and swelling while keeping the battery pack compact and minimizing volume increase
3Volume of stationary object
If the battery pack structure is made more compact to reduce volume, then space efficiency improves, but the ability to absorb impact and swelling is reduced
Solution Approach 1:
The patent uses flexible thin films that can deform under impact and swelling forces. These thin films provide the necessary compliance and absorption capability within a compact structure, allowing the battery pack to maintain small volume while still protecting against mechanical damage
Solution Approach 2:
The patent incorporates porous sponge materials with controlled thickness (1mm or less) that can compress and expand to absorb swelling and impact. The porous structure allows these thin elements to provide adequate cushioning functionality without occupying excessive space, maintaining compactness while improving reliability
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 reliability by absorbing shock and swelling, preventing volume increase, and maintaining a compact structure, ensuring durability and efficient use of space.
Implementation Method 1
a first tape, stiffer than a second tape, with a gap between them to absorb impact
Implementation Method 2
a compressible second tape to absorb swelling
Data Source
AI summary
A battery pack includes a battery cell stack in which a plurality of battery cells are stacked and battery cell junctions are disposed between the battery cells. Each of the battery cell junctions includes a first tape arranged to correspond to an edge of a surface of one of the battery cells and a second tape arranged to correspond to a central portion of the surface of the one of the battery cells. The first tape and the second tape form a single layer and are spaced apart from each other.