Battery Pack Resin Layer Thickness Control
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Solution Overview
Problem
Laminated lithium ion secondary battery packs face challenges with low mechanical strength and dimensional accuracy, leading to increased thickness and weight, and coverage failures during resin molding, which affect the battery pack's characteristics.
Innovation Solution
A battery pack design where a resin layer with a specific viscosity (80 mPa·second to less than 1000 mPa·second) is used to form a thickness of 0.05 mm to smaller than 0.4 mm on the main surfaces of the battery, preventing coverage failures and enhancing mechanical strength by varying the thickness of the resin molding at side surfaces compared to main surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the resin molding at side surfaces is increased to improve mechanical strength, then mechanical strength is improved, but coverage failure occurs where part of the main surfaces is not covered with molded resin
Solution Approach 1:
The patent applies different resin molding thicknesses to different locations: thicker resin molding (greater than 1 mm) at side surfaces for mechanical strength, and thinner resin molding (0.1-1 mm) at main surfaces to prevent coverage failure. This local differentiation resolves the contradiction between improving strength and maintaining coverage uniformity.
2Weight of stationary object
If a laminated lithium ion secondary battery is used to reduce thickness and weight, then thickness and weight are reduced, but dimensional variation is great and mechanical strength is low
Solution Approach 1:
The patent combines the laminated lithium ion secondary battery with resin molding to create a composite structure. The resin molding compensates for the low mechanical strength and great dimensional variation of the laminated battery, while maintaining the weight and thickness advantages. This composite approach resolves the contradiction between reduced weight and maintained strength.
3Ease of manufacture
If resin molding is used to integrate battery components, then integration is achieved, but coverage failure occurs affecting battery pack characteristics
Solution Approach 1:
The patent differentiates resin molding thickness by location: thinner molding (0.1-1 mm) at main surfaces ensures complete coverage and prevents coverage failure, while thicker molding at side surfaces provides structural support. This local quality differentiation maintains both integration efficiency and coverage accuracy.
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
The solution effectively prevents coverage failures and improves mechanical strength, maintaining battery pack characteristics while reducing thickness and weight, thus enhancing energy density and reliability.
Implementation Method 1
a reaction curable resin having a viscosity of not less than 80 mPa·second to less than 1000 mPa·second
Implementation Method 2
A molten resin is injected into the molding space and subsequently cured to obtain the battery pack
Data Source
AI summary
A battery pack includes: a battery having a main surface; and a resin layer capable of being integrated with an armor member armoring the battery so that at least a part of the main surface of the battery is exposed and covering the main surface of the battery, wherein the resin layer is formed by curing a reaction curable resin having a viscosity of not less than 80 mPa·second to less than 1000 mPa·second and a thickness of the resin layer on the main surface of the battery ranges from 0.05 mm to smaller than 0.4 mm.