Battery Pack Coupling Reinforcement for Impact Resistance
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Solution Overview
Problem
Lithium secondary battery packs deteriorate in quality due to loosening of component coupling under external impact, necessitating improved resistance mechanisms.
Innovation Solution
A battery pack design featuring a frame case with channel grooves and a coupling reinforcement portion made from bonding materials like urethane or modified silicone, containing ceramics, to enhance the coupling strength between the bare cell and the frame case, along with a metal label for increased durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional coupling methods are used between bare cell and frame case, then the structure is simple, but the coupling strength is insufficient and components loosen under external impact
Solution Approach 1:
The frame case is divided into multiple sections with channel grooves created at specific locations. The coupling reinforcement portion is segmented into discrete bonding material placements within these grooves, allowing targeted strengthening without requiring complete structural redesign of the entire frame case.
Solution Approach 2:
The coupling reinforcement portion uses composite bonding materials that combine organic polymers (urethane or modified silicone) with inorganic ceramic particles. This composite structure provides both adhesive bonding properties and enhanced mechanical strength to resist external impacts effectively.
2Strength
If bonding material with high shrinkage rate is used, then the bonding process is simple, but the coupling strength deteriorates due to excessive shrinkage during curing
Solution Approach 1:
The bonding material formulation is optimized to control the shrinkage rate within a specific range (20% or less) during curing. This parameter optimization ensures sufficient bonding strength while preventing excessive shrinkage that would create gaps or stress concentrations between the coupling reinforcement portion and the bare cell.
Solution Approach 2:
The composite bonding material combines polymers with ceramic particles to achieve balanced shrinkage characteristics. The ceramic particles provide structural stability and reduce overall shrinkage during curing, while the polymer matrix ensures adequate adhesion to both the frame case and bare cell surfaces.
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
The design significantly improves the battery pack's resistance to external impacts, such as bending or twisting, thereby enhancing reliability and quality by maintaining strong coupling between components.
Implementation Method 1
The coupling reinforcement portion can include a bonding material. The coupling reinforcement portion can include a bonding material selected from a group consisting of urethane and modified silicone.
Implementation Method 2
The coupling reinforcement portion can include a bonding material exhibiting a shrinkage rate of 20% or less upon a curing process.
Implementation Method 3
The coupling reinforcement portion can include a bonding material that includes a ceramic. An amount of the ceramic can be in a range of 20 wt % to 80 wt % based on the total weight of the bonding material.
Data Source
AI summary
A battery pack having increased resistance against external impact by increasing a coupling strength between a bare cell and a case, resulting in increased reliability and quality. The battery pack includes a bare cell, a circuit module electrically connected to the bare cell, a frame case surrounding the bare cell and including a channel groove arranged at a region facing the bare cell, a coupling reinforcement portion arranged in the channel groove to couple the frame case to the bare cell and a metal label attached to side surfaces of the bare cell.