Breakpoint Insulation Film With Tear Lines for Battery Pack Alignment
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Solution Overview
Problem
Conventional insulating films used in new energy vehicle battery packs face challenges in positioning accuracy due to processing inaccuracies, leading to deviations in positioning holes, which affect the connection and insulation of cylindrical batteries.
Innovation Solution
A breakpoint insulating film with electrode holes, positioning hole groups, and tear line groups is designed, featuring diagonally arranged circular and oval-shaped positioning holes, staggered tear lines, and adjustable tear lines that can be torn to adjust positioning accuracy and prevent leakage, allowing for improved alignment and insulation between the insulating film and flexible circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple positioning holes are processed on the insulating film for longer battery packs, then positioning coverage is improved, but positioning accuracy deteriorates due to processing deviations
Solution Approach 1:
The insulating film is divided into multiple detachable sections along tearing lines. Each section can be independently positioned and fixed to the flexible circuit, allowing localized precise positioning rather than requiring high precision across the entire large-area film.
Solution Approach 2:
The insulating film transitions from a fixed rigid structure to a dynamic adjustable structure through the tearing lines. Users can tear the film along predetermined lines to adjust the position and size of positioning hole groups, enabling adaptive positioning accuracy adjustment based on actual installation requirements.
2Ease of manufacture
If the insulating film is made as a single fixed structure, then manufacturing is simple, but positioning accuracy cannot be adjusted
Solution Approach 1:
The insulating film incorporates tearing lines that divide it into detachable sections. This segmentation allows the film to be manufactured as a single piece with simple geometry, yet enables post-manufacturing adjustment by tearing along the lines to achieve precise positioning.
Solution Approach 2:
The structure changes from fixed to adjustable through the tearing lines. By tearing the film along predetermined lines, users can change the position and configuration of positioning hole groups, transforming the film from a static single-structure to an adjustable multi-configuration structure.
3Ease of manufacture
If positioning hole groups are fixed in position, then manufacturing is easy, but positioning accuracy cannot be optimized
Solution Approach 1:
The positioning hole groups are no longer fixed in position but can be adjusted by tearing the insulating film along predetermined tearing lines. This dynamic adjustment capability allows optimization of positioning accuracy while maintaining simple manufacturing of the initial structure.
Solution Approach 2:
The insulating film is segmented by tearing lines that pass through or near positioning hole groups. This segmentation enables independent adjustment of each positioning hole group's position relative to the flexible circuit, allowing precise positioning optimization without complex manufacturing.
Data Source
AI summary
A breakpoint insulating film includes an insulating film body laminated on the surface of the flexible circuit. The insulating film has a main body that includes a battery connection area, and the battery connection area is provided with several electrode holes. The battery connection area is along the insulating film body. Several positioning hole groups are provided in the length direction, and the adjacent positioning holes include several breakpoint tearing line groups between the positioning hole groups. A split line group runs through the battery connection along the width direction of the insulating film body. The film has a simple structure and can be adjusted to a certain position through a tearing line group. The position of the positioning hole group improves the positioning between the insulating film and the flexible circuit.