Battery Pack Insulator Folded Structure Impact Absorption
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Solution Overview
Problem
Existing battery packs face challenges in ensuring secure insulation and absorbing external impact forces between the circuit module and the bare cell, particularly in polymer batteries with solid polymer electrolytes and lithium-ion batteries using organic solvent electrolytes.
Innovation Solution
A battery pack design that includes a bare cell, a circuit module arranged in parallel to the bare cell's terrace portion, and a holder surrounding both surfaces, with an insulator of increased thickness to enhance insulation and absorb external impacts, featuring a folded insulator structure and a holder with shield portions to securely support the circuit module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin insulator is used between the circuit module and the terrace portion, then the device complexity is reduced, but the insulation performance is insufficient and external impact forces cannot be absorbed
Solution Approach 1:
The insulator is folded into a multi-layer structure, transitioning from a single-layer thin insulator to a multi-layer thick insulator. This dimensional transformation increases the insulation thickness and impact absorption capability without significantly increasing the horizontal space occupation, thereby resolving the contradiction between insulation performance and device complexity.
Solution Approach 2:
The folded insulator structure is designed in advance to provide both insulation and impact absorption. By pre-folding the insulator to create a multi-layer structure, the patent ensures that the insulator can absorb external impact forces before they reach the circuit module or battery cell, while maintaining adequate insulation performance.
2Reliability
If the circuit module is directly placed on the terrace portion without a holder, then the device complexity is reduced, but the insulation performance and mechanical support are insufficient
Solution Approach 1:
The holder is designed to perform multiple functions simultaneously: it provides mechanical support for the circuit module, maintains the folded insulator structure, and contributes to impact absorption. This multi-functionality reduces the need for separate components, thereby minimizing the increase in device complexity while improving insulation performance.
Solution Approach 2:
The holder integrates the support function and insulator retention function into a single component. By merging these functions, the patent avoids adding separate support structures and insulator retention mechanisms, thus reducing the overall device complexity while ensuring adequate insulation performance.
3Reliability
If a folded insulator structure is used, then the insulation thickness is increased, but the manufacturing process becomes more complex
Solution Approach 1:
The insulator is folded in advance during the assembly process, before the circuit module is installed. This preliminary folding action allows the insulator to be prepared in its final multi-layer configuration before being placed between the circuit module and the terrace portion, simplifying the overall manufacturing process by separating the folding operation from the final assembly steps.
Data Source
AI summary
The present disclosure provides a battery pack. The battery pack includes: a bare cell; a circuit module arranged in parallel to a terrace portion of the bare cell and connected to a tab of the bare cell; and a holder surrounding two surfaces of the circuit module and the terrace portion of the bare cell.