Battery Pack Assembly with Insulating Adhesive and Cooling Resin
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Solution Overview
Problem
Conventional battery packs face issues with insulation performance due to the lack of insulation in the heat conductive resin layer, which can lead to damage when the battery cell is compromised, and there is a need for improved cooling efficiency.
Innovation Solution
A battery pack design that includes a module-less structure without a module frame, using insulating adhesive layers and partitioned heat conductive resin layers to maintain insulation and enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a battery pack is disassembled into a battery module and battery pack housing for repair or replacement, then the battery pack can be maintained or upgraded, but connection errors may occur during reassembly affecting battery performance
Solution Approach 1:
The battery pack is divided into modular components (battery module and housing) that can be independently handled. The connection structure includes separate positioning features on both the housing and battery module that guide precise alignment during reassembly, eliminating connection errors while maintaining ease of repair.
Solution Approach 2:
A positioning structure acts as an intermediary mechanism between the battery module and housing. This positioning structure includes positioning protrusions and corresponding positioning recesses that automatically align the components during assembly, ensuring accurate connections without requiring high skill level from technicians.
2Reliability
If battery packs are designed with complex internal structures to prevent short circuits, then safety is improved, but the complexity of disassembly and reassembly increases
Solution Approach 1:
The connection structure is segmented into distinct positioning features (protrusions and recesses) that are distributed at multiple locations. This segmentation maintains safety by ensuring proper alignment at each connection point while keeping the overall assembly process simple through repetitive, standardized features.
Solution Approach 2:
The positioning structures use uniform, standardized features throughout the battery pack design. All positioning protrusions and recesses follow the same geometric patterns and dimensions, which simplifies the disassembly and reassembly process while maintaining consistent safety standards across all connection points.
3Ease of repair
If technicians perform disassembly and reassembly operations, then repair and replacement are enabled, but connection errors and short circuits may occur
Solution Approach 1:
The positioning structure is pre-configured with positioning protrusions and recesses that automatically guide correct alignment during assembly. This preliminary design feature prevents connection errors before they can occur, eliminating short circuit risks while maintaining ease of repair.
Solution Approach 2:
The positioning structure acts as a preventive measure that cushions against potential connection errors. By providing built-in alignment guidance through positioning features, the design preemptively protects against short circuits that could result from improper reassembly by technicians.
Data Source
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AI summary
A battery pack according to one embodiment of the present disclosure includes a battery cell stack that is formed by stacking a plurality of battery cells, an adhesive layer that is applied to the lower surface of the battery cell stack, a lower pack housing that has a plurality of module regions and on which the battery cell stack is mounted, and a heat conductive resin layer that is located between the adhesive layer and the lower pack housing, wherein the adhesive layer has an insulation property.