Battery Pack Friction Sheet Assembly for Lateral Stiffness
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Solution Overview
Problem
Existing battery packs face challenges in assembly cost and time, lateral stiffness, and impact resistance, particularly when used in high-power applications like electric vehicles, due to the arrangement of multiple battery cells.
Innovation Solution
A battery pack design incorporating a heat insulating sheet and alternating first and second friction sheets with non-adhesive and adhesive surfaces, along with a restraining mechanism, to provide compressive force and enhance lateral stiffness and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are assembled in a battery pack, then output voltage and current are increased, but assembly cost and assembly time increase
Solution Approach 1:
The battery pack is divided into modular units with standardized components (friction sheets, heat insulating sheets, restrainers) that can be pre-assembled and then quickly combined. This segmentation allows for parallel assembly processes and reduces the time required to assemble multiple battery cells into a complete pack.
Solution Approach 2:
Multiple functional components (friction sheets for positioning, heat insulating sheets for thermal management, restrainers for structural support) are combined into a single integrated assembly layer that is installed between battery cells. This merging reduces the number of separate assembly steps and lowers overall assembly time and cost.
2Power
If multiple battery cells are assembled in a battery pack, then output current is increased, but assembly cost increases
Solution Approach 1:
The friction sheets and heat insulating sheets serve multiple functions simultaneously: they provide lateral positioning, thermal insulation, friction-based restraint, and structural alignment. This multi-functionality reduces the number of separate components needed, lowering material costs and assembly complexity while enabling higher output current through increased cell density.
Solution Approach 2:
The restrainer applies compressive force to change the physical state of the battery cell assembly, creating friction between components that enhances lateral stiffness. This parameter change (applying compression) improves structural integrity without requiring additional expensive materials or complex fastening mechanisms, reducing overall assembly cost while supporting higher current output.
3Volume of moving object
If battery cells are arranged in longitudinal direction, then space utilization is improved, but lateral stiffness is reduced
Solution Approach 1:
Friction sheets are introduced as intermediary components between battery cells arranged in the longitudinal direction. These sheets provide friction-based resistance to lateral forces, maintaining compact longitudinal arrangement for space efficiency while adding the necessary lateral stiffness through frictional engagement with the cell surfaces.
Solution Approach 2:
The restrainer applies compressive force to the battery cell assembly, increasing the normal force between components. This parameter change enhances friction between the friction sheets and battery cell surfaces, thereby increasing lateral stiffness without altering the longitudinal arrangement that provides space utilization efficiency.
4Quantity of substance
If battery cells are closely arranged, then energy density is increased, but impact resistance is reduced
Solution Approach 1:
Heat insulating sheets and friction sheets are pre-positioned between closely arranged battery cells to provide thermal and mechanical cushioning. These sheets absorb and distribute impact forces before they can propagate through the cell assembly, protecting the high-density arrangement from damage while maintaining close spacing for energy density.
Solution Approach 2:
The battery pack employs composite material layers (friction sheets with specific friction coefficients, heat insulating sheets with thermal and mechanical properties) between battery cells. These composite materials provide both thermal management and impact resistance, enabling close cell arrangement for high energy density while maintaining reliability under external impacts.
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 reduces assembly costs and time while improving lateral stiffness and impact resistance, ensuring the battery cells remain stable and aligned under external forces, and effectively managing thermal interference between cells.
Implementation Method 1
a heat insulating sheet between two adjacent battery cells of the plurality of battery cells
Implementation Method 2
a first friction sheet located between the heat insulating sheet and a first battery cell of the two adjacent battery cells
Implementation Method 3
a restrainer configured to provide a compressive force in the longitudinal direction from opposite ends of the plurality of battery cells
Data Source
AI summary
A battery pack includes a plurality of battery cells arranged in a longitudinal direction, a heat insulating sheet between two adjacent battery cells of the plurality of battery cells, a first friction sheet located between the heat insulating sheet and a first battery cell of the two adjacent battery cells and including non-adhesive surfaces in direct contact with the heat insulating sheet and the first battery cell, and a restrainer configured to provide a compressive force in the longitudinal direction from opposite ends of the plurality of battery cells.