Rechargeable Battery Packing Tray with Impact-Absorbing Structure
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Solution Overview
Problem
Current packing mechanisms for rechargeable batteries, including cell barrier members and shock-absorbing materials, complicate the packing process, increase material costs, and require time for insertion and separation, while also being disposable and costly.
Innovation Solution
A rechargeable battery packing tray with a design featuring a bottom and inner wall forming a receiving space, including a stepped portion and reinforcement wall to support cylindrical battery cells, made from recyclable materials like ABS, PET, or pulp, which simplifies insertion and separation and reduces costs by using a double-layered structure with impact-absorbing features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cell barrier members and shock-absorbing materials are used to protect battery cells, then protection reliability is improved, but packing complexity and material cost increase
Solution Approach 1:
The patent combines the protection function and shock-absorption function into a single integrated tray structure. The tray includes a bottom wall and side walls that form a receiving space, with integrated reinforcement ribs and curved bottom surfaces that provide both structural support and impact protection, eliminating the need for separate barrier members and shock-absorbing materials.
Solution Approach 2:
The tray structure serves multiple functions simultaneously: it provides mechanical support for the battery cell, absorbs external impacts through its curved bottom wall and reinforcement ribs, prevents cell-to-cell contact through the receiving space design, and facilitates automated handling through its standardized geometry. This multi-functional design reduces overall packing complexity.
2Reliability
If disposable packing materials are used to ensure protection, then reliability is improved, but cost increases
Solution Approach 1:
The tray is designed to be reusable rather than disposable. The robust structure with reinforcement ribs and integrated protection features allows the tray to be recovered and reused across multiple packing cycles, eliminating the need for continuous consumption of new packing materials and reducing overall material costs.
3Reliability
If traditional packing mechanisms with multiple components are used, then protection is improved, but insertion and separation time increases
Solution Approach 1:
The patent extracts and eliminates unnecessary intermediate components from the packing system. By integrating all protection and support functions into a single tray structure, the design removes multiple separate components that would require sequential assembly and disassembly operations, thereby reducing insertion and separation time.
4Ease of manufacture
If a simple tray structure is used to reduce cost, then manufacturing cost decreases, but protection capability is reduced
Solution Approach 1:
The tray employs local quality enhancement through strategically placed reinforcement ribs at high-stress areas, curved bottom walls for impact distribution, and thickened wall sections at connection portions. These localized structural enhancements provide maximum protection where needed while maintaining overall manufacturing efficiency and cost-effectiveness.
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 tray reduces packing costs and simplifies the handling of battery cells by providing a stable and impact-absorbing structure that is recyclable, facilitating efficient and cost-effective packing and protection of battery cells.
Implementation Method 1
The bottom can include an impact absorbing portion protruding to an outer side of the receiving space to set a first height difference ΔH1 with the bottom
Data Source
AI summary
A packing tray for a rechargeable battery is disclosed. In one aspect, the tray includes a bottom portion and an inner wall connected to the bottom portion. The bottom portion and the inner wall define a receiving space configured to receive a battery cell. The inner wall includes upper and lower portions. The lower portion extends upwardly, and the upper portion is outwardly curved such that the upper portion is wider than the lower portion.