Battery Pack Curable Resin Terminal Insulation

Solution Overview

Problem

Existing battery pack designs that fill the entire case with potting resin increase weight, material cost, and risk of impact propagation, while also restricting size changes in batteries during charging and discharging.

Innovation Solution

A battery pack design featuring a secondary battery with external terminals covered by curable resin within an internal case, reducing the amount of potting resin used and allowing for a buffer against impacts, while accommodating size changes in the battery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the whole inside the case is filled with potting resin, then electrical insulation, water resistance, and vibrational impact resistance are improved, but the weight of the battery pack increases

Engineering Contradiction:

Improveelectrical insulation and water resistanceVSAvoidweight of battery pack

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent applies local quality by selectively filling only the gap region between the battery module and case with curable resin, rather than filling the entire case. This localized application provides electrical insulation and water resistance precisely where needed (at the interface between battery and case) while minimizing resin用量 and reducing overall weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements partial action by filling only the necessary gap space with curable resin, rather than completely filling the entire case. This partial filling approach provides sufficient protection for electrical insulation and water resistance while avoiding the excessive weight and cost associated with complete case filling.

Inventive Principle:

Principle #16Partial or excessive action

2Reliability

If the whole inside the case is filled with potting resin, then electrical insulation and water resistance are improved, but the material cost and filling time increase

Engineering Contradiction:

Improveelectrical insulation and water resistanceVSAvoidfilling time and material cost

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies local quality by selectively filling only the gap region between the battery module and case with curable resin, rather than filling the entire case. This localized application provides electrical insulation and water resistance precisely where needed (at the interface between battery and case) while minimizing resin用量 and reducing overall weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements partial action by filling only the necessary gap space with curable resin, rather than completely filling the entire case. This partial filling approach provides sufficient protection for electrical insulation and water resistance while avoiding the excessive weight and cost associated with complete case filling.

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If the inside of the case is filled with potting resin without a gap, then protection is improved, but impact propagation cannot be properly relaxed

Engineering Contradiction:

ImproveprotectionVSAvoidimpact propagation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies beforehand cushioning by intentionally maintaining a gap between the battery module and case, rather than completely filling the space with rigid resin. This gap acts as a cushioning layer that can absorb and dissipate impact energy, preventing rigid transmission of external impacts to the battery while the resin provides protection against electrical insulation, water, and vibration.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Reliability

If the whole battery is covered with potting resin, then protection is improved, but size changes during charging and discharging are restricted

Engineering Contradiction:

ImproveprotectionVSAvoidsize change accommodation

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by selectively filling only the gap region between the battery module and case with curable resin, rather than filling the entire case. This localized application provides electrical insulation and water resistance precisely where needed (at the interface between battery and case) while minimizing resin用量 and reducing overall weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies beforehand cushioning by intentionally maintaining a gap between the battery module and case, rather than completely filling the space with rigid resin. This gap acts as a cushioning layer that can absorb and dissipate impact energy, preventing rigid transmission of external impacts to the battery while the resin provides protection against electrical insulation, water, and vibration.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 design reduces the amount of potting resin, lowers manufacturing costs, and enhances impact resistance while allowing for size changes in the battery, thus improving overall performance and durability.

Implementation Method 1

for ensuring and improving electrical insulation, water resistance, vibrational impact resistance, and heat dissipation of internal heat generation

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

for ensuring and improving electrical insulation, water resistance, vibrational impact resistance, and heat dissipation of internal heat generation

Methodology Applied

Scientific EffectWater resistance: Hydrophobe

Implementation Method 3

for ensuring and improving electrical insulation, water resistance, vibrational impact resistance, and heat dissipation of internal heat generation

Methodology Applied

Scientific EffectHeat dissipation: Conduction (thermal)

Data Source

PatentUS20230090932A1Battery pack, electric-powered tool, and electric-powered vehicle

Publication Date: 2023.03.23 MURATA MFG CO LTD

AI summary

A battery pack includes a secondary battery, an external case, an internal case housed inside the external case, and a circuit board, the secondary battery includes a first external terminal and a second external terminal, the first external terminal and the second external terminal are housed in the internal case, and at least the first external terminal and the second external terminal are covered with a curable resin in the internal case.