Battery Pack Manufacturing System with Sequential Pressure and Restraining Member
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Solution Overview
Problem
Existing battery pack manufacturing systems face issues with warpage due to reaction forces after pressure cancellation, affecting the quality of the battery pack.
Innovation Solution
A manufacturing system comprising a front-half unit and a rear-half unit that apply pressures sequentially to a stack of cells, with the rear-half unit using a restraining member to maintain pressure and reduce warpage by applying a second, smaller pressure after the initial pressure has been applied for a certain period.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure is applied to the stack in a single direction while restricting the position of the stack, then the stack is compressed and warpage is limited, but when pressure is cancelled the reaction force causes the stack to warp
Solution Approach 1:
The patent applies preliminary compression to the stack during manufacturing to pre-set its shape and reduce subsequent warpage. By compressing the stack before final assembly and maintaining restrictive positioning, the system prepares the stack in advance to resist reaction forces that would otherwise cause warping after pressure release.
Solution Approach 2:
The patent applies counter-pressure or restrictive forces in advance to counteract the anticipated reaction force that will occur when compression is released. The restraining member is positioned to provide opposing force that prevents the stack from warping when the primary compression pressure is cancelled.
2Productivity
If the stack is restrained by the restraining member and pressure application is cancelled, then the manufacturing process is complete, but the reaction force causes warpage that adversely affects battery pack quality
Solution Approach 1:
The patent maintains continuous restrictive action on the stack throughout the manufacturing process. The restraining member remains engaged with the stack during and after compression, ensuring that the beneficial compressive effect continues without interruption, thereby preventing warpage even after the primary pressure is released.
Solution Approach 2:
The restraining member is positioned and configured in advance to cushion or absorb the reaction force that will occur when compression pressure is released. This pre-positioned restraint acts as a buffer that prevents the sudden warping motion that would otherwise occur when pressure is cancelled.
3Device complexity
If a single pressure application method is used, then the process is simple, but warpage occurs due to reaction force after pressure cancellation
Solution Approach 1:
The patent divides the pressure application system into multiple independent pressure application portions (front-half and rear-half units). Each portion can apply pressure independently to different regions of the stack, allowing for more precise control of compression forces and better prevention of warpage compared to a single pressure application method.
Solution Approach 2:
The patent transitions from single-direction pressure application to multi-directional pressure application by adding front-half and rear-half pressure application portions. This dimensional expansion of the pressure application system allows for more comprehensive control of the stack during compression, preventing warpage that would occur with simple single-direction pressure.
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 approach minimizes warpage by ensuring continuous pressure application, reducing the reaction force and maintaining the stack's integrity within the restraining member, thereby enhancing the quality and stability of the battery pack.
Implementation Method 1
a front-half unit that applies a first pressure to press the stack in the single direction for a certain period of time
Implementation Method 2
a rear-half unit that applies a second pressure to press the stack in the single direction after the front-half unit presses the stack
Implementation Method 3
a front-half restriction portion that comes into contact with the stack to restrict a position of the stack
Data Source
AI summary
A manufacturing system for a battery pack includes a front-half unit that applies a first pressure to press a stack in a single direction for a certain period of time and a rear-half unit that then causes a restraining member to restrain the stack while applying a second pressure smaller than the first pressure to press the stack in the single direction. The front-half unit includes a front-half pressure application portion that presses the stack and a front-half restriction portion that restricts a position of the stack. The front-half pressure application portion presses the stack with the front-half restriction portion in contact with the stack. The rear-half unit includes a rear-half pressure application portion that presses the stack and a rear-half restriction portion that restricts the position of the stack. The rear-half pressure application portion presses the stack with the front-half or rear-half restriction portion in contact with the stack.