Battery Pack Adhesion Member for Bent Pouch Cells
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Solution Overview
Problem
Existing battery packs face challenges in ensuring reliable adhesion and preventing electrical short-circuits between pouch-type batteries, particularly due to exposed metal layers at bent parts, which can lead to mechanical and electrical failures.
Innovation Solution
The use of thermosetting tape as an adhesion member, shaped to cover ends of bent parts and applied between pouch-type batteries, along with a clamp to insulate and mechanically secure the connections, enhances adhesion reliability and prevents electrical short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pouch-type batteries are connected directly without adhesion members, then the device complexity is reduced, but the reliability of connection and insulation is compromised due to exposed metal layers at bent parts
Solution Approach 1:
An adhesion member is introduced as an intermediary component between the first and second pouch-type batteries. This adhesion member serves dual functions: it mechanically adheres the bent parts of adjacent batteries together and provides electrical insulation to prevent short-circuits between exposed metal layers, thereby resolving the contradiction between connection reliability and structural complexity.
2Ease of manufacture
If bent parts of pouch-type batteries are left exposed, then the manufacturing process is simpler, but electrical short-circuits may occur between adjacent batteries
Solution Approach 1:
The adhesion member acts as an insulating intermediary that covers the exposed metal layers at bent parts of pouch-type batteries. By positioning this insulating component at the interface between adjacent batteries, the solution prevents electrical short-circuits while maintaining manufacturing simplicity, as the adhesion member is applied during the assembly process without requiring additional insulation steps.
3Strength
If adhesion members are used to connect bent parts, then the adhesion strength is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The adhesion member combines multiple functions into a single component: mechanical adhesion through bonding surfaces and electrical insulation through its insulating material properties. This merging of functions improves adhesion strength between bent parts while avoiding the need for separate insulation components, thereby limiting the increase in manufacturing process complexity.
4Device complexity
If the bent parts of batteries are not insulated, then the device structure is simpler, but mechanical failures may occur due to poor adhesion
Solution Approach 1:
The adhesion member serves as a mediating component that simultaneously addresses mechanical adhesion and electrical insulation requirements. By introducing this single intermediary element at the interface of bent parts, the solution improves mechanical adhesion reliability without significantly complicating the overall device structure, as the adhesion member integrates both protective functions.
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 solution provides robust adhesion and insulation, ensuring reliable connections between batteries, preventing electrical short-circuits and reinforcing the battery pack structure, thereby improving overall performance and safety.
Implementation Method 1
an adhesion member interposed between the bent part of the first battery and the bent part of the second battery and adhering the bent part of the first battery to the bent part of the second battery
Implementation Method 2
a clamp covering the second surface of the bent part of the first battery, the second surface of the bent part of the second battery, and the end of the bent part of the first battery and the end of the bent part of the second battery
Data Source
AI summary
A battery pack includes a first battery and a second battery each having a bent part at one side; and an adhesion member interposed between the bent part of the first battery and the bent part of the second battery and adhering the bent part of the first battery to the bent part of the second battery.


