Elastic Spacer Stabilizes Battery Unit Cells
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rechargeable battery packs face instability due to unit cells moving within the case under physical impacts, leading to potential damage in the connections between the unit cells and the connection tab, and between the connection tab and the cable, as well as dimensional dispersion.
Innovation Solution
A rechargeable battery pack design that includes a case with spacers made of elastic material to stably fix unit cells by exerting an elastic force, with compressing portions and elastic portions arranged to securely position and compress the unit cells, and a support structure to guide the insertion and maximize the number of cells housed, along with a connection tab and cable system for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unit cells are housed in a case without additional fixing structures, then the device complexity is reduced, but the unit cells move under physical impacts causing connection damage and dimensional dispersion
Solution Approach 1:
The patent uses elastic spacers with compressing portions made of elastic material to fix the unit cells. These flexible elastic components exert continuous elastic force to hold the unit cells firmly in position, preventing movement under physical impacts while maintaining structural simplicity.
Solution Approach 2:
The elastic spacers are pre-installed in the case to provide beforehand cushioning and fixing for the unit cells. When unit cells are inserted, the elastic spacers automatically exert compressive force to secure them, preventing damage from subsequent physical impacts without requiring additional complex fixing structures.
2Reliability
If rigid supports are used to fix unit cells, then the unit cells are firmly held, but the structure becomes more complex and rigid
Solution Approach 1:
The patent replaces rigid support structures with flexible elastic spacers that have compressing portions. These elastic components bend and deform to accommodate unit cells while exerting continuous fixing force, achieving reliable fixation without the complexity of rigid mechanical support structures.
Solution Approach 2:
The patent changes the physical state of the fixing mechanism from rigid to elastic. The elastic spacers can dynamically adjust their compressive force based on the insertion state of unit cells, providing adaptive fixing that is both simple and reliable.
3Reliability
If multiple fixing structures are added to prevent unit cell movement, then the stability improves, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the functions of support, fixing, and cushioning into a single integrated elastic spacer component. This merged structure eliminates the need for multiple separate fixing structures, simplifying both the design and manufacturing process while maintaining reliable unit cell positioning.
Solution Approach 2:
The elastic spacers are designed to automatically perform the fixing function when unit cells are inserted. The elastic deformation and recovery of the spacers provides self-adjusting fixation without requiring complex assembly procedures or additional fastening operations.
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 design effectively stabilizes the unit cells against physical impacts, maintains secure connections between the unit cells and the connection tab, and prevents dimensional dispersion, ensuring the battery pack's structural integrity and operational reliability.
Implementation Method 1
the elastic portion including the elastic material and configured to exert the elastic force and to push the first and second compressing portions in opposite directions against adjacent unit cells
Data Source
AI summary
A rechargeable battery pack includes a plurality of unit cells adjacent to each other, each unit cell including a rechargeable battery, a case configured to house the unit cells and support side surfaces thereof, and a spacer compressed among the unit cells, the spacer including an elastic material and configured to exert an elastic force to support the unit cells.