Curved Battery Pack Insulating Case Segmentation
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Solution Overview
Problem
The increasing demand for battery packs that can fit various shapes of portable electronic devices, particularly curved devices, is not adequately met by existing technologies, which often compromise on durability and safety due to inflexible design.
Innovation Solution
A battery pack design featuring a curved can with a cap assembly and insulating case, comprising first and second insulating units symmetrically arranged around an electrode pin, allowing for curvature adjustment to match device shapes while maintaining electrical insulation and safety through specific through-holes and electrolyte solution inlets, and using metallic materials for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the battery pack uses a fixed rigid structure, then manufacturing and assembly are simplified, but it cannot adapt to various shapes of portable electronic devices especially curved devices
Solution Approach 1:
The insulating case is divided into a first insulating unit and a second insulating unit that can be relatively moved with respect to each other. This segmentation allows the battery pack to change its shape by adjusting the relative positions of the two insulating units, enabling adaptation to various device shapes including curved surfaces while maintaining a relatively simple overall structure.
2Adaptability or versatility
If the battery pack uses a curved design to match device shapes, then adaptability improves, but durability and safety may be compromised due to inflexible design
Solution Approach 1:
The insulating case incorporates dynamic adjustability through the first and second insulating units that can be relatively moved. This dynamic structure allows the battery pack to be configured for curved shapes when needed while maintaining structural integrity and safety, as the units can be positioned to provide necessary support and protection.
Solution Approach 2:
The insulating case uses insulating materials that provide both the necessary electrical insulation and mechanical strength. The composite structure of the first and second insulating units maintains durability and safety while enabling curved configurations.
3Reliability
If the insulating case is made as a single integrated unit, then manufacturing is simpler, but it cannot provide proper electrical insulation around the electrode pin in curved configurations
Solution Approach 1:
The insulating case is segmented into first and second insulating units with specific functional assignments. The first insulating unit provides electrical insulation around the electrode pin, while the second insulating unit complements this function. This segmentation ensures proper electrical insulation in curved configurations while keeping each unit manufacturable.
Data Source
AI summary
A battery pack includes a can having a curvature and an opening at a side thereof; an electrode assembly accommodated in the can; a cap assembly including a cap plate sealing the opening of the can and an electrode pin in a center of the cap plate; and an insulating case between the electrode assembly and the cap assembly, the insulating case including a first insulating unit and a second insulating unit that are separated from each other.