Battery Potting Clamshell Structure for Vibrational Wear Reduction
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Solution Overview
Problem
Mechanically coupling multiple battery cells is challenging, especially for large numbers, as existing methods lack effective solutions for secure and efficient connection.
Innovation Solution
The use of a clamshell structure with recesses and adhesives, where batteries are sandwiched between planar clamshells with protrusions and adhesives to ensure secure mechanical connection, allowing for efficient interconnection and improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple battery cells are mechanically coupled together, then the structural integrity and stability are improved, but the complexity of connection methods increases
Solution Approach 1:
The battery pack is divided into modular units with individual battery cells that can be independently connected through standardized clamshell structures. Each clamshell unit contains specific数量的电池 cells arranged in defined configurations, allowing the overall battery pack to be assembled from repeating modular segments rather than requiring complex custom connections for each cell.
Solution Approach 2:
Multiple battery cells are merged into a single integrated clamshell structure that provides both mechanical support and electrical connection pathways. The clamshell combines structural housing, adhesive bonding, and electrical contact functions into one unified component, reducing the number of separate connection elements needed.
2Strength
If adhesive is used to bond battery cells, then the mechanical connection strength is improved, but the heat dissipation capability may be worsened
Solution Approach 1:
The adhesive is applied selectively at specific locations within the clamshell structure rather than uniformly across all surfaces. Thermal interface materials or conductive pathways are incorporated at critical heat generation points, creating localized zones of enhanced thermal management while maintaining structural bonding where needed.
Solution Approach 2:
The bonding system uses composite materials that combine structural adhesive properties with thermal management capabilities. The clamshell structure incorporates multiple material layers including adhesives for mechanical bonding and thermally conductive materials for heat dissipation, allowing simultaneous achievement of strong mechanical connection and effective thermal management.
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 method provides a robust and durable connection that reduces vibrational wear, enhances heat exchange, and maintains a stable voltage, effectively addressing the challenge of connecting multiple battery cells.
Implementation Method 1
a first adhesive against gravity to a first internal (battery side) surface of a first clamshell
Data Source
AI summary
One embodiment includes a bottom clamshell and a top clamshell sandwiching a first battery and a second battery, with a fill port extending from a top surface of the top clamshell through to the bottom surface of the top clamshell and to a space between the first and second batteries. The embodiment includes a protrusion coupled to the top clamshell proximate to the fill port and extending into the space, wherein the protrusion at least partially occludes a direct path through the fill port to the space.