Battery Module Reinforcement Layout for Drop and Pressure Loads
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Solution Overview
Problem
Battery modules in mobile electronic products often fail drop and pressure tests due to insufficient structural strength on the bottom, particularly in the insulating sheet's protective layer.
Innovation Solution
A battery module design featuring a carrying structure with a frame and structurally enhancing portions that extend outward from the insulating sheet, providing additional support and enhancing the module's structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If only a frame and insulating sheet are used in the carrying structure, then the device complexity is reduced, but the structural strength on the outer surface is insufficient causing failure in drop and pressure tests
Solution Approach 1:
The carrying structure is divided into distinct functional components: a frame for mounting battery units, insulating sheets for electrical isolation, and structurally enhancing portions for mechanical strength. This segmentation allows each component to be optimized independently while working together to solve the contradiction between simplicity and strength.
Solution Approach 2:
The structurally enhancing portions extend outward from the insulating sheet in a direction perpendicular to the main battery module body, adding structural strength in the Z-direction (thickness direction) without significantly increasing the footprint area. This dimensional extension provides the needed structural reinforcement while maintaining a compact form factor.
2Strength
If the insulating sheet is made thicker to improve protective strength, then the structural strength is enhanced, but the volume of the battery module increases
Solution Approach 1:
The protective function is segmented between the insulating sheet and the structurally enhancing portions. The insulating sheet maintains its primary electrical isolation function with minimal thickness, while the extending structurally enhancing portions provide the mechanical protection needed, eliminating the need to increase insulating sheet thickness for structural purposes.
Solution Approach 2:
Instead of increasing thickness in the Z-direction to improve structural strength, the solution extends structurally enhancing portions outward from the insulating sheet surface. This approach provides structural reinforcement through lateral extension rather than vertical thickening, maintaining compact volume while enhancing protective strength.
Data Source
AI summary
Discussed is a battery module that may include at least one battery unit, a carrying structure and at least one insulating sheet, wherein the carrying structure includes a frame and at least one structurally enhancing portion connected to each other, and the frame mounts the battery unit. Further, the insulating sheet can be installed in the carrying structure to cover the battery unit, and the structurally enhancing portion extends outward of the battery module past an outer surface of the insulating sheet in a first direction.