Battery Pack Structural Adhesive Cell Fixation
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Solution Overview
Problem
The existing battery pack manufacturing process is complex and costly due to the need for a frame structure and multiple components, which increases the number of components and complicates the assembly process.
Innovation Solution
A battery pack design that omits the frame structure by using a structural adhesive to adhere cells directly to the housing, reducing the number of components and simplifying the manufacturing process, while also incorporating a thermal conductive adhesive for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a frame structure and multiple components are used to assemble cells in modules, then the cells can be fixed and heat dissipation can be achieved, but the number of components increases and the manufacture process becomes complicated
Solution Approach 1:
The patent combines multiple functions (fixation and heat dissipation) into a single structural adhesive material, eliminating the need for separate frame structures and thermal pads. The structural adhesive simultaneously provides mechanical bonding and thermal conduction pathways, reducing component count while maintaining reliability
Solution Approach 2:
The structural adhesive serves multiple functions: it acts as a bonding agent to fix cells to the housing, provides thermal conduction for heat dissipation, and eliminates the need for separate frame structures. This multi-functional approach simplifies the overall device complexity
2Reliability
If cells are first adhered with each other and then mounted in module frame structures, then proper fixation and heat dissipation are achieved, but the manufacturing cost increases
Solution Approach 1:
The patent merges the functions of adhesion and thermal management into a single structural adhesive material, eliminating the need for separate components like frame structures and thermal pads. This reduction in component count directly lowers manufacturing costs while maintaining reliable cell fixation and heat dissipation
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components (frame structures, separate thermal pads) from the traditional assembly process. By taking out these redundant elements and replacing them with a single multi-functional adhesive, the manufacturing process becomes simpler and less costly
3Reliability
If a frame structure and modules are used in the battery pack, then cells can be properly assembled and fixed, but the battery pack height increases and volume energy density decreases
Solution Approach 1:
The patent combines the fixation function and thermal management function into the structural adhesive itself, eliminating the need for separate frame structures and modules. This integration allows cells to be directly mounted to the housing, significantly reducing battery pack height and improving volume energy density
Solution Approach 2:
The patent removes intermediate frame structures and module components that increase battery pack height. By extracting these unnecessary layers and using structural adhesive for direct cell-to-housing attachment, the overall pack dimensions are reduced, improving volume energy density
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
This design simplifies the manufacturing process, reduces costs, lowers the battery pack height, and enhances heat dissipation efficiency, thereby improving the volume energy density ratio.
Implementation Method 1
A structural adhesive is filled between a bottom of the housing and the plurality of cells. The plurality of cells are adhered to the housing through the structural adhesive.
Implementation Method 2
the structural adhesive is a thermal conductive structural adhesive
Data Source
AI summary
The present disclosure relates to the technical field of assembly of a battery pack, and particularly, to a battery pack. The battery pack includes a housing. A plurality of cells is arranged in interior of the housing. A structural adhesive is filled between a bottom of the housing and the plurality of cells, and the plurality of cells is adhered to the housing through the structural adhesive. In the battery pack provided in the present disclosure, the cells are arranged in the interior of the housing, and the housing is adhered to the cells through the structural adhesive. The structural adhesive can functions as fixing the cells, such that a frame structure of a module can be omitted, the number of components in the battery pack can be reduced, manufacture process can be reduced, assembling efficiency can be improved, and manufacturing cost can be reduced.