Battery Module Adhesive Strap with Elastic Adjuster
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Solution Overview
Problem
Conventional laminated polymer lithium batteries are prone to damage during removal due to the adhesiveness of double-sided tapes used for assembly, leading to potential tears in the battery core.
Innovation Solution
A battery module design incorporating an adhesive strap with an adjuster and elastic elements, where the adhesive layers are positioned between the strap and the base, allowing for secure attachment and removal without direct adhesion between the battery pack and the base, thereby preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If double-sided tape is used to adhere the battery pack to the base, then the battery pack is securely attached, but the battery core can be torn and damaged during removal
Solution Approach 1:
An adhesive strap is introduced as an intermediary component between the battery pack and the base. The strap includes an attached portion with adhesive that contacts the base, while the battery pack is secured to the strap through mechanical means (buckle and elastic element). This mediator transfers the attachment function away from direct contact between the battery pack and base, preventing adhesive damage to the battery core during removal while maintaining secure attachment.
2Ease of manufacture
If double-sided tape is used to adhere the battery pack, then assembly is simple, but removal causes damage to the battery core
Solution Approach 1:
The adhesive strap serves as a mediator that simplifies assembly while protecting the battery core. The strap is attached to the base using double-sided tape, and the battery pack is then secured to the strap using a buckle mechanism. This approach maintains assembly simplicity while enabling damage-free removal, as the strap absorbs the adhesive interaction rather than the battery pack itself.
Solution Approach 2:
The attachment system is segmented into distinct functional components: the adhesive strap (with attached portion, adjusted portion, and fixed portion), the buckle, and the elastic element. This segmentation allows the adhesive function to be isolated to the strap rather than directly contacting the battery pack, enabling simple assembly while preventing core damage during removal.
3Strength
If a secure attachment mechanism is used, then the battery pack is firmly fixed, but removal becomes difficult and may damage the battery
Solution Approach 1:
The attachment mechanism incorporates dynamic elements including an elastic element that provides flexible holding force and a buckle that can be easily engaged and disengaged. The elastic element maintains firm attachment during normal use while allowing controlled release during removal. The adjuster mechanism enables dynamic adjustment of the strap tension, providing secure fixation that can be easily released without damaging the battery.
4Strength
If adhesive is applied directly to the battery pack, then attachment is strong, but the adhesive damages the battery core during removal
Solution Approach 1:
The adhesive is applied to the attached portion of the strap rather than directly to the battery pack. The strap acts as an intermediary that bears the adhesive strength requirements, while the battery pack interacts with the strap through mechanical fastening. This separation ensures that adhesive forces are concentrated on the strap material designed to withstand them, preventing adhesive damage to the battery core during removal.
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 ensures secure attachment of the battery pack while preventing external damage during removal by distributing the adhesive forces through the strap and elastic elements, allowing for easy detachment without tearing the battery core.
Implementation Method 1
The adjuster is positioned on the adjusted portion and has a buckle and an elastic element. The buckle is positioned between the elastic element and the battery pack
Data Source
AI summary
A battery module includes a battery pack, a strap, and an adjuster. The strap has an attached portion, an adjusted portion and a fixed portion. The attached portion is attached to the battery pack, and the adjusted portion extends from one side of the attached portion. The fixed portion extends from the other side of the attached portion. The adjuster is positioned on the adjusted portion and has a buckle and an elastic element. The buckle is positioned between the elastic element and the battery pack. The elastic element and the battery pack oppose to the same side of the strap. The adjusted portion of the strap passes through the buckle. The battery pack with the strap and the adjuster is fixed on the plate base for protecting itself against outside damage.