Battery Pack Potting Structure for Uniform Adhesive Filling
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Solution Overview
Problem
Existing battery pack designs face issues with non-uniform adhesive filling, which affects the stability and strength of the battery module within the case.
Innovation Solution
A battery pack design that includes a blocking structure dividing the filling space into separate compartments, allowing for precise application of filling adhesive in each compartment, with varying volumes and foaming rates to ensure uniformity and improved connection between the battery module and the case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the filling space is filled with adhesive in a conventional manner, then the battery module is connected to the case, but the adhesive distribution is non-uniform, affecting stability and strength
Solution Approach 1:
The filling space is divided into multiple separate filling compartments using blocking structures (blocking ribs or blocking plates). This segmentation allows adhesive to be applied uniformly in each compartment rather than having non-uniform distribution in a single large space, directly resolving the contradiction between manufacturing precision and strength.
2Manufacturing precision
If the filling space is divided into multiple compartments, then adhesive distribution uniformity is improved, but the device complexity increases
Solution Approach 1:
The blocking structures are designed as simple blocking ribs or blocking plates that divide the filling space into compartments. These segmented structures achieve uniform adhesive distribution while maintaining relatively simple geometry and manufacturing processes, balancing manufacturing precision with device complexity.
Solution Approach 2:
The blocking structures serve multiple functions: they divide the filling space into compartments for uniform adhesive distribution, provides structural support, and facilitate the potting process. This multi-functionality reduces the need for additional components, thereby limiting the increase in device complexity.
3Reliability
If varying volumes of adhesive are applied in different compartments, then the potting effect is improved, but the manufacturing process becomes more complex
Solution Approach 1:
Different filling compartments can accommodate different volumes of adhesive based on their specific space requirements and structural needs. This local quality approach allows optimized potting effect in each compartment while maintaining a relatively straightforward manufacturing process through standardized blocking structures.
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
Enhances the pressure resistance, stiffness, and adhesive potting effect by ensuring uniform adhesive distribution, thereby improving the overall stability and strength of the battery pack.
Implementation Method 1
a filling adhesive filled in the plurality of filling compartments, to connect the battery module to the inner wall of the battery pack case
Data Source
AI summary
A battery pack includes a battery pack case, a battery module, a blocking structure and a filling adhesive. The battery pack case defines a battery cavity, the battery module is positioned in the battery cavity, and the battery module is spaced apart from at least part of an inner wall of the battery cavity to define a filling space. The blocking structure has a first side connected to the outer wall of the battery module and a second side abutted against an inner wall of the battery pack case, and is configured to divide the filling space into a plurality of separate filling compartments. The filling adhesive is filled in the plurality of filling adhesives, to connect the battery module to the inner wall of the battery pack case.