Battery Pack Insulating Tape Layout for Clean Wire Routing
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Solution Overview
Problem
Existing battery packs face issues with adhesive leakage during laser cutting, leading to unwanted adhesion and interference with external wires, which disrupts the trajectory and causes noise during repeated attachment and detachment.
Innovation Solution
The insulating tape in the battery pack is designed with regions of varying adhesive strengths, including a first region with strong adhesion and a second region with weak or no adhesion, formed through laser cutting to prevent adhesive exposure and minimize physical interference with external wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the insulating tape is cut by laser to separate adhesive regions, then the adhesive strength distribution is improved, but adhesive leakage occurs during cutting
Solution Approach 1:
The insulating tape is divided into multiple regions with different adhesive strengths: a first region with strong adhesive strength for securing the battery cell, and a second region with weak or no adhesive strength for allowing wire passage. This segmentation resolves the contradiction by providing both secure attachment and adhesive-free zones to prevent leakage and interference with external wires.
Solution Approach 2:
Different regions of the insulating tape are assigned different adhesive properties: the first region (inner region) has strong adhesive strength while the second region (peripheral region) has weak or no adhesive strength. This local differentiation allows the tape to simultaneously achieve secure bonding where needed and prevent adhesive interference with wires where not needed.
2Strength
If the insulating tape has strong adhesive strength throughout, then the battery cell is securely fixed, but external wires are interfered with and adhesion noise occurs
Solution Approach 1:
The adhesive layer is segmented into different functional zones: a first adhesive region providing strong bonding to secure the battery cell, and a second adhesive region with reduced or eliminated adhesive properties to allow clean wire passage without adhesion noise during repeated attachment and detachment.
Solution Approach 2:
The insulating tape exhibits spatially varying adhesive properties: strong adhesive strength in the first region for secure fixation, and weak or no adhesive strength in the second region for wire-friendly zones, thereby preventing adhesion noise while maintaining secure mounting.
3Strength
If the adhesive layer covers the entire insulating tape, then maximum bonding is achieved, but wire trajectory is disrupted and unwanted adhesion occurs
Solution Approach 1:
The adhesive layer is segmented to cover only the necessary bonding areas (first region) while leaving wire passage areas (second region) free of adhesive or with reduced adhesive properties, thereby achieving maximum bonding strength where needed while ensuring smooth wire trajectory without unwanted adhesion.
Solution Approach 2:
The adhesive layer is selectively applied: present and strong in the first region for bonding, and absent or weak in the second region for wire-friendly zones, optimizing both bonding strength and wire trajectory ease.
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 design prevents adhesive leakage and unwanted adhesion, ensuring smooth wire trajectory and reducing adhesion noise, thereby enhancing the reliability and stability of the battery pack's electrical connections.
Implementation Method 1
an adhesive layer on an inner surface of the tape substrate, the first region of the insulating tape may include a first portion of the tape substrate and the adhesive layer
Data Source
AI summary
A battery pack includes a battery cell including a first main surface and a second main surface facing each other, a circuit unit on an upper surface of the battery cell, the upper surface of the battery cell connecting the first main surface and the second main surface of the battery cell to each other, and an insulating tape extending from the first main surface to the second main surface of the battery cell while surrounding the circuit unit, the insulating tape including a first region and a second region having different adhesive strengths from each other.