Battery Pack Bonding Upper Cover to Modules
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Solution Overview
Problem
The existing battery packs have low overall rigidity due to the separation of the upper cover from the battery modules, leading to a higher likelihood of busbar breakage during vibration tests, which can result in short circuits and potential fires or explosions.
Innovation Solution
A battery pack design where the upper cover is sealed to the lower enclosure with a first bonding member on the upper surface of the battery modules, enhancing the connection strength and rigidity by using a structural adhesive or similar bonding mechanism, and a second bonding member on the lower surface connecting the modules to the enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the upper cover is not connected to the battery modules, then the assembly process is simple, but the overall rigidity of the battery modules is low
Solution Approach 1:
The patent connects the upper cover to the battery modules through bonding members (adhesive tapes), merging previously separate components into an integrated structure. This combination maintains assembly simplicity while significantly improving the overall rigidity and structural strength of the battery pack.
2Ease of operation
If the upper cover is not connected to the battery modules, then the structure is flexible and easy to assemble, but the busbars are more prone to break during vibration tests
Solution Approach 1:
By bonding the upper cover to the battery modules, the patent creates a unified structural system that provides better support and protection for the busbars during vibration tests, thereby improving reliability without compromising assembly ease.
Solution Approach 2:
The bonding members provide pre-established structural support and cushioning for the busbars before vibration tests occur, preventing breakage by ensuring the busbars are securely positioned and supported within the integrated structure.
3Ease of manufacture
If the upper cover is not connected to the battery modules, then the manufacturing process is straightforward, but short circuits and fires may occur due to busbar breakage
Solution Approach 1:
The patent integrates the upper cover with the battery modules through bonding, creating a structurally sound enclosure that prevents busbar breakage and the subsequent harmful effects of short circuits, fires, and explosions, while maintaining manufacturing simplicity.
Solution Approach 2:
The patent transforms the potential harm of loose connections and busbar breakage into a benefit by using bonding members that securely attach the upper cover, converting a risky separate-structure design into a safe integrated structure that prevents catastrophic failures.
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 significantly improves the rigidity of the battery pack, reducing the risk of busbar breakage and subsequent fires or explosions during vibration tests by ensuring a secure connection between the upper cover and the battery modules.
Implementation Method 1
a first bonding member on an upper surface of the plurality of battery modules, the first bonding member connecting the plurality of battery modules to the upper cover
Data Source
Figure 1~2
Figure 3~4
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AI summary
The invention relates to a battery pack, which includes an enclosure comprising an upper cover 1 and a lower enclosure 3 in sealed connection, a plurality of battery modules 2 arranged in the enclosure, and a first bonding member 4 disposed on the upper surface of the battery modules 2 and intended for connecting the battery modules 2 with the upper cover 1. Unlike the prior art, the above technical solution employs a first bonding member 4 disposed on the upper surface of the battery modules 2 and intended for connecting the battery modules 2 with the upper cover 1. So the battery modules 2 are connected with the upper cover 1 via the first bonding member 4 to form a whole, which strengthens the connection strength between the upper cover 1 and the battery modules 2, and improves the overall rigidity of the battery modules 2.