Battery Pack Frame Case Warp Prevention Design
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Solution Overview
Problem
The challenge lies in creating a battery pack that balances the need for reduced size and weight while maintaining safety and reliability, as smaller secondary batteries can compromise their structural integrity and manufacturing efficiency.
Innovation Solution
A battery pack design featuring a frame case with warp-preventing portions and a combination of steel and resin materials, formed through insert injection molding, which surrounds bare cells and includes a top case with protective circuitry to enhance safety and prevent deformation during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the size and weight of secondary batteries are decreased to meet portable device requirements, then the batteries become more suitable for small portable devices, but the structural integrity and safety of the batteries deteriorate
Solution Approach 1:
The frame case is constructed using composite materials consisting of a steel material core surrounded by resin material. This composite structure provides both the lightweight特性 needed for portable devices and the structural strength required for safety, resolving the contradiction between weight reduction and structural integrity maintenance.
2Volume of moving object
If the size of secondary batteries is decreased, then the batteries fit better in portable devices, but warping and deformation occur during manufacturing
Solution Approach 1:
The frame case is designed with pre-formed warp preventing portions that are integrated into the structure before battery assembly. These preventive structural features are built in during frame case manufacturing, preventing warping issues before they occur during subsequent battery assembly and manufacturing processes.
3Device complexity
If simpler battery pack designs are used to reduce complexity, then manufacturing becomes easier, but structural strength and warp prevention capability are reduced
Solution Approach 1:
Multiple functions are merged into the frame case structure: the steel-resin composite material simultaneously provides strength, lightweight特性, and warp prevention. The warp preventing portions are integrated directly into the frame case rather than being separate components, reducing overall device complexity while maintaining structural integrity.
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 enhances the structural strength and durability of the battery pack, prevents warping and cracking, and simplifies the manufacturing process, resulting in a more reliable and efficient production of compact battery packs.
Implementation Method 1
The frame case may include the steel material and the resin material, and may be formed through insert injection molding.
Data Source
AI summary
A battery pack includes one or more bare battery cells, a frame case, and a top case. Each of the bare battery cells has first and second electrode tabs. The frame case surrounds an outer surface of the one or more bare cells. The top case is coupled to the frame case at one end of the one or more bare cells. In the battery pack, the frame case includes a warp preventing portion parallel to the top case.