Elastic Battery Module Housing for Bend and Impact Protection
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Solution Overview
Problem
Existing battery modules lack impact resistance, flexibility, and design versatility, limiting their application in wearable devices and requiring protection against damage from bending and impact.
Innovation Solution
A battery module design featuring a first exterior body made of an elastic material, such as rubber, with a two-step molding process to prevent damage and allow bending, and a second exterior body that changes shape independently from the battery, ensuring high impact resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard exterior body is used to protect the battery, then impact resistance is improved, but flexibility and bendability deteriorate
Solution Approach 1:
The patent uses a composite exterior body structure combining a flexible base material (such as rubber or polymer) with a protective layer. This composite structure provides both flexibility for bending and impact resistance through the protective layer, resolving the contradiction between softness and hardness requirements.
Solution Approach 2:
The exterior body is designed as a flexible shell that can bend without damaging the battery. The shell incorporates protective features while maintaining flexibility, allowing the battery module to adapt to curved surfaces and wearable applications while still protecting against impact.
2Adaptability or versatility
If a film is used as the exterior body to achieve flexibility, then bendability is improved, but impact resistance deteriorates
Solution Approach 1:
The patent combines a flexible film material with a protective coating or layered structure. The base film provides bendability while the additional protective layer or composite structure enhances impact resistance, allowing both requirements to be satisfied simultaneously.
Solution Approach 2:
The exterior body has different properties in different regions - the main body remains flexible for bending while specific areas (such as corners or impact-prone zones) have enhanced protective characteristics. This local differentiation allows the structure to be both flexible and impact-resistant where needed.
3Reliability
If the exterior body is made rigid to prevent damage, then reliability is improved, but adaptability to different mounting positions deteriorates
Solution Approach 1:
The exterior body is designed as a flexible shell that can conform to different mounting positions and surfaces. The shell maintains protective capabilities while adapting its shape, allowing the battery module to be mounted in various positions including curved surfaces for wearable devices.
Solution Approach 2:
The exterior body incorporates dynamic flexibility, allowing it to change shape as needed for different mounting configurations while maintaining structural integrity. This dynamic adaptability enables the same protective structure to work across multiple mounting positions and device types.
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 battery module with enhanced impact resistance, flexibility, and design versatility, allowing easy attachment and detachment to electronic devices, while preventing damage from bending and ensuring long-term use.
Implementation Method 1
The first exterior body includes an elastic material. The first exterior body includes a first portion, a second portion, and a space surrounded by the first portion and the second portion. The second exterior body is provided in the space. The first portion and the second portion are bonded to each other. The second portion is in contact with part of the tabs and an end portion of the second exterior body.
Data Source
AI summary
A battery module with high impact resistance is provided. A battery module using an elastic body such as rubber for its exterior body covering a battery is provided. A bendable battery module is provided. As the exterior body covering a battery, an elastic body such as rubber is used, and the exterior body is molded in two steps. First, a first portion provided with a depression in which a battery is stored is molded using a first mold. Next, a battery is inserted into the first portion. Subsequently, second molding is performed using a second mold so as to fill an opening of the depression in the first portion, so that a second portion is formed. The second portion serves as a cover for closing the opening of the depression in the first portion. The second portion is formed in contact with part of the electrodes in the battery and part of an end portion of the second exterior body in the battery.