Battery Pack Air-Flow Sealing with Interlocking Resin Frames
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Solution Overview
Problem
In battery packs with a cell stack and air-flow path, the compressive force can cause the cell stack to curve, leading to a risk of air leakage between the air-flow path and the cell stack due to the resin frame being raised from the sealing member.
Innovation Solution
The battery pack design includes resin frames with first and second protrusions that engage with adjacent frames to maintain sealing, and the use of foam resin sealing members that deform outward to prevent air leakage, with optional clearance grooves and projections to enhance sealing effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sealing member is used to seal the gap between the air-flow path and the cell stack, then the structure is simple, but air leakage occurs when the cell stack curves under compressive force
Solution Approach 1:
The sealing member is divided into two distinct parts: a first sealing member that contacts the central portion of the cell stack and a second sealing member that contacts the end portions. This segmentation allows each sealing member to independently handle different regions, preventing air leakage even when the cell stack curves under compressive force.
2Reliability
If the resin frame is pressed against the sealing member to seal the gap, then sealing is achieved, but the resin frame may be raised from the sealing member when the cell stack curves, causing air leakage
Solution Approach 1:
Different regions of the resin frame are designed with different functions: the central portion presses the first sealing member to seal the central gap, while the end portions are positioned to engage with the second sealing member. This local differentiation ensures that both central and end sealing are maintained even when the cell stack curves under compressive force.
3Stability of the object's composition
If the cell stack is compressed from both ends toward the center, then the cell stack is stabilized, but the cell stack may curve upward, raising the resin frame from the sealing member
Solution Approach 1:
The resin frame is pre-configured with extended end portions that reach toward the second sealing member before compression occurs. This preliminary positioning ensures that when the cell stack curves under compressive force, the extended end portions are already in position to engage with the second sealing member and prevent air leakage at the ends.
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 effectively prevents air from leaking out between the air-flow path and the cell stack, ensuring reliable sealing and preventing air leaks even under compressive forces that might cause the cell stack to curve.
Implementation Method 1
the sealing member pressed by air abuts against the second protrusion
Data Source
AI summary
A battery pack includes: a cell stack (CS) in which rectangular cells and resin frames (RFs) are alternately stacked; a case housing CS and including an air-flow path (AFP) extending in a longitudinal direction of CS in a bottom surface; and a pair of sealing members (PoSM) extending along both edges of AFP on the bottom surface of the case, and sealing a gap between AFP and CS. RF includes a partition plate partitioning adjacent cells, and a rib dividing air fed from AFP, formed on a surface of the partition plate. Each of the RFs includes, at both ends of a bottom thereof, a pair of first protrusions protruding downward so as to press PoSM from above, and engaging with that of an adjacent RF; and a pair of second protrusions protruding downward on an outer side of PoSM, and engaging with that of the adjacent RF.