Battery Pack Reinforcing Tape Composite Structure
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Solution Overview
Problem
Conventional battery packs are vulnerable to fracture or dislodging due to external impact, particularly at the connection sections between bare cells, leading to increased thickness and difficulty in forming a thin, robust case.
Innovation Solution
A battery pack design featuring a multi-cell assembly with opposing planar surfaces, a protection circuit, a surrounding case, and reinforcing tape attached to the planar surfaces, which includes a protection circuit board with connectors and lead terminals, and an insulator to enhance cohesive strength, along with a holder and case formed by injection molding, all contributing to increased strength and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a thin case is formed through injection molding to reduce battery pack thickness, then the battery pack becomes more compact, but the wide surface of the injection case becomes vulnerable to external impact
Solution Approach 1:
The patent combines the injection-molded case material with adhesive and reinforcing tape materials to create a composite structure. The reinforcing tape is attached to the outer surface of the case, forming a composite material system that provides both thin profile and high impact resistance, resolving the contradiction between compactness and strength.
Solution Approach 2:
The reinforcing tape is selectively applied to the wide outer surfaces of the case that are most vulnerable to external impact. This local reinforcement approach maintains the overall thin profile of the battery pack while providing targeted strength enhancement where it is most needed, addressing the contradiction between thickness and impact resistance.
2Device complexity
If the battery pack uses a frame case with only an outer frame to reduce complexity, then the structure is simpler, but the battery pack is vulnerable to fracture or dislodging of bare cells by external impact at connection sections
Solution Approach 1:
The patent uses adhesive as a flexible bonding medium between the case and the reinforcing tape, and between the case and the battery cells. This flexible adhesive layer allows the structure to absorb impact forces without rigid fracture, maintaining reliability while keeping the case structure relatively simple.
Solution Approach 2:
By combining the frame case structure with reinforcing tape attached via adhesive, the patent creates a composite system that maintains structural simplicity while significantly enhancing protection against fracture and dislodging at connection sections between bare cells.
3Strength
If reinforcing elements are added to increase case strength, then impact resistance improves, but the battery pack thickness increases
Solution Approach 1:
The reinforcing tape used in the patent is a thin film element that provides substantial reinforcement without adding significant thickness. When combined with the thin adhesive layer, this approach increases impact resistance while maintaining a compact overall profile, resolving the contradiction between strength and thickness.
Data Source
Figure 1A
Figure 1B
Figure 2A~2C
AI summary
A battery pack includes a multi cell assembly having a plurality of bare cells, the multi cell assembly defining opposing planar surfaces. The battery pack also includes a protection circuit at one side of the multi cell assembly, a case surrounding a periphery of the multi cell assembly and the protection circuit and exposing the opposing planar surfaces of the multi cell assembly to an exterior of the multi cell assembly and reinforcing tape attached to the opposing planar surfaces.