Battery Pack Frame Case with Ribs for Bending Resistance
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Solution Overview
Problem
The manufacturing process of battery packs is complicated by the need for insulating tape, and existing designs often result in a lack of structural integrity, making them prone to bending.
Innovation Solution
A battery pack design that eliminates the need for insulating tape by using a frame case with ribs and undercuts to securely hold the bare cell, enhancing structural integrity and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating tape is used in the manufacturing process, then electrical insulation is achieved, but the manufacturing process becomes complicated
Solution Approach 1:
The frame case integrates both structural support and electrical insulation functions into a single component. The frame case is made of insulating material (such as plastic or polymer) that provides both mechanical framework and electrical isolation, eliminating the need for separate insulating tape layers and simplifying the manufacturing process.
Solution Approach 2:
The insulating tape is completely removed from the battery pack structure. Instead of adding insulating tape as a separate component, the frame case itself is designed with insulating properties, extracting the insulation function from a separate element and incorporating it into the main structural component.
2Ease of manufacture
If traditional battery pack structure is used, then assembly is simple, but structural integrity is poor and the pack is easily bent
Solution Approach 1:
The frame case includes multiple ribs extending from the main body toward the bare cell. These ribs segment the structural support function into multiple reinforcing elements that distribute mechanical loads and prevent bending, while still forming an integrated piece that maintains assembly simplicity.
Solution Approach 2:
The frame case is made of insulating material with enhanced structural properties, combining electrical insulation capability with mechanical strength. This composite approach allows the single component to provide both insulation and structural reinforcement without requiring additional materials or complex assembly.
3Reliability
If the frame case covers the entire outside of the bare cell, then protection is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The frame case serves multiple functions simultaneously: it provides structural support, electrical insulation, mechanical protection, and positioning for the bare cell. This multi-functionality is achieved through a single integrated component design that covers essential areas without requiring complex manufacturing processes or additional parts.
Solution Approach 2:
The frame case provides coverage and protection at specific critical locations rather than uniformly across the entire bare cell. The ribs are positioned to reinforce areas most susceptible to bending, and the frame case covers essential structural areas while leaving other areas open, providing targeted protection without excessive complexity.
Data Source
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AI summary
A battery pack that does not utilize an insulating tape simplifies a manufacturing processes of the external case and furthermore the battery pack has improved resistance against bending. The battery pack includes a chargeable and dischargeable bare cell, a circuit member electrically coupled to the bare cell, and a frame case to cover an entire outside surface of the bare cell excluding a pair of long sides of the bare cell. The frame case includes at least two round parts.