Battery Pack Support Foot Thermal Welding Attachment
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Solution Overview
Problem
Contemporary battery packs with support feet attached using double-sided tape face issues with detachment over time or under strong external forces, as the adhesion decreases, leading to instability and potential loss of protection against impact and slipping.
Innovation Solution
A support foot design featuring a first support part made from rubber and a second support part made from plastic with a protrusion, where the protrusion is inserted into a through hole in the case and thermally welded, eliminating the need for double-sided tape and enhancing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If double-sided tape is used to attach the support foot to the battery pack, then the attachment process is simple and easy to manufacture, but the adhesion strength decreases over time and under strong external force
Solution Approach 1:
The support foot is constructed using composite materials: a rubber-based first support part for cushioning and a plastic-based second support part for structural integrity and thermal welding. This composite structure enables both easy attachment and strong, reliable adhesion by combining the advantages of different materials.
Solution Approach 2:
The patent replaces the mechanical adhesion system (double-sided tape) with a thermal welding system. The protrusion on the second support part is thermally welded to the battery pack case, providing strong and permanent attachment that does not degrade over time, while still maintaining manufacturing simplicity.
2Device complexity
If only double-sided tape is used to adhere the support foot, then the device complexity is low, but the support foot may detach under strong external force
Solution Approach 1:
The support foot is divided into two distinct parts: the first support part (rubber) and the second support part (plastic). This segmentation allows each part to serve its specific function - cushioning and structural support respectively - while enabling a more robust attachment method through the protrusion feature on the second part.
Solution Approach 2:
The patent changes the attachment parameter from chemical adhesion (double-sided tape) to thermal welding. This parameter change dramatically increases attachment strength while maintaining reasonable device complexity, as the thermal welding process integrates seamlessly with existing manufacturing workflows.
3Reliability
If a protrusion with thermal welding is added to the support foot, then the attachment strength and stability are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the support foot structure with the attachment mechanism by integrating the protrusion directly into the second support part. This combination eliminates the need for separate attachment components, reducing overall device complexity while achieving strong and stable attachment through thermal welding.
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 provides a stronger and more stable attachment of the support foot to the battery pack, preventing detachment and ensuring protection against external impacts and slipping, while maintaining a compact design.
Implementation Method 1
the protrusion is inserted into a through hole in the case and thermally welded
Data Source
AI summary
A support foot for a battery pack, a battery pack including the support foot and a method for manufacturing the battery pack are provided. The support foot is constructed with a first support part, and a second support part including a protrusion. The protrusion is inserted into the battery pack and is thermally welded to be attached to the battery pack, so that the support foot can be securely attached to the battery pack.