Battery Pack Exterior Member with Adhesive Openings
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Solution Overview
Problem
Battery packs face defects in their exterior appearance due to manufacturing inefficiencies, leading to degradation in process efficiency, particularly in achieving a small and lightweight design while maintaining reliability.
Innovation Solution
A battery pack design incorporating an exterior member with an adhesive layer and a base material layer, featuring openings adjacent to the contact points of the bare cells' side surfaces, along with a frame that supports the cells and includes chamfered corners and guide portions, to enhance the attachment and reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the exterior member is manufactured using thin film material to achieve small size and light weight, then the battery pack size and weight are reduced, but defects in exterior appearance frequently occur
Solution Approach 1:
The exterior member is manufactured using thin film material to achieve small size and light weight of the battery pack, as stated in the background section. The thin film material allows the battery pack to meet size and weight requirements while the adhesive layer with openings provides structural support to prevent appearance defects
Solution Approach 2:
The exterior member is formed as a composite structure consisting of a base material layer and an adhesive layer with openings. This composite design combines the lightweight properties of thin film material with the structural integrity provided by the adhesive layer, resolving the contradiction between weight reduction and manufacturing precision
2Device complexity
If the adhesive layer is provided without openings, then the exterior member structure is simpler, but tunnel-shaped spaces may form causing defects in exterior appearance
Solution Approach 1:
The adhesive layer is provided with one or more openings to prevent tunnel-shaped spaces from forming between the exterior member and the cells. These openings allow the adhesive to properly bond the exterior member to the frame and cells, ensuring complete attachment without voids that would cause appearance defects
Solution Approach 2:
Openings are extracted from the adhesive layer to eliminate the harmful tunnel-shaped spaces. By removing material from the adhesive layer to create openings, the design prevents the formation of voids and ensures proper bonding, thereby improving exterior appearance quality
3Strength
If the exterior member is tightly attached to the frame, then structural integrity is improved, but manufacturing process complexity increases
Solution Approach 1:
The adhesive layer is pre-formed with openings before attachment to the frame and cells. This preliminary preparation ensures that the adhesive is properly positioned and configured to create tight attachment, while the openings guide the bonding process and prevent void formation, making the manufacturing process more controllable
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 improves process efficiency by reducing defects in the exterior appearance and ensuring secure attachment of the exterior member to the frame, preventing tunnel-shaped spaces and enhancing the structural integrity and manufacturing reliability of the battery pack.
Implementation Method 1
an exterior member composed of an adhesive layer provided adjacent to the bare cells while surrounding a portion of the bare cells, and a base material layer provided on the adhesive layer
Data Source
AI summary
A battery pack includes one or more bare cells and an exterior member. Each of the bare cells has a pair of long side surfaces opposite to each other, and short side surfaces that connect the long side surfaces. The exterior member is composed of an adhesive layer provided adjacent to the bare cells while surrounding a portion of the bare cells, and a base material layer provided on the adhesive layer. In the battery pack, the adhesive layer has one or more openings therein, and the opening is provided adjacent to a portion at which the long and short side surfaces of the bare cell come in contact with each other.