Battery Pack Expandable Enclosure for X-Axis Swelling Relief
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Solution Overview
Problem
Battery swelling due to excessive heat and electrolyte decomposition leads to increased internal pressure, potentially causing the battery enclosure to break open, which can result in damage to electronic devices by expanding along the Z-axis, compromising their thin design and profile.
Innovation Solution
A battery pack design featuring an expandable portion with an inner and outer layer, including a gap portion without a sealing layer, allowing fluid communication when pressure exceeds a threshold, enabling the battery pack to expand along the X-axis instead of the Z-axis, thereby directing swelling and reducing the risk of enclosure rupture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery enclosure is designed to be sealed and robust to withstand high pressure, then the battery can maintain longevity and structural integrity, but the battery expansion will cause the enclosure to break open or the device to crack when swelling occurs
Solution Approach 1:
The enclosure is segmented into a sealed portion and an expandable portion with distinct functions. The sealed portion maintains structural integrity and protects internal components, while the expandable portion accommodates battery swelling through controlled deformation via fold lines, preventing uncontrolled rupture
Solution Approach 2:
The expandable portion is designed with flexible material that can deform elastically to accommodate battery expansion. The fold lines create hinge-like structures that allow controlled bending and expansion in specific directions without compromising the overall enclosure integrity
2Stress or pressure
If the battery swelling is allowed to expand along the Z-axis to accommodate internal pressure, then the battery can release stress, but the electronic device thickness increases and the device may crack or break
Solution Approach 1:
The expandable portion is positioned asymmetrically on one side of the battery enclosure rather than being uniformly distributed. This asymmetric design allows the enclosure to expand preferentially in the X-direction at the designated expandable portion, preventing Z-axis expansion that would increase device thickness
Solution Approach 2:
The invention redirects the expansion from the Z-axis (thickness direction) to the X-axis (lateral direction) by providing a compliant path through the expandable portion. The fold lines guide the deformation along specific geometric paths that convert vertical expansion into lateral expansion
3Reliability
If the seal is made strong to prevent fluid leakage, then the battery remains sealed, but the seal may break open under high pressure causing electrolyte loss
Solution Approach 1:
The sealing system is segmented into a sealed portion with high-integrity seals and an expandable portion that accommodates pressure through deformation rather than seal failure. This segmentation allows the seal to remain intact while the expandable portion handles stress relief
Solution Approach 2:
The expandable portion acts as a cushioning element that absorbs and distributes internal pressure before it can build up to levels that would cause seal failure. The fold lines create a progressive deformation mechanism that gradually accommodates expansion, preventing sudden seal rupture
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 solution effectively manages battery swelling by redirecting expansion along the X-axis, reducing the likelihood of enclosure damage and maintaining the device's thin profile, while ensuring the battery pack remains sealed until a predetermined pressure threshold is met.
Implementation Method 1
the sealing layer allowing for fluid communication between the gap portion and the interior space when a pressure exerted on the sealing layer exceeds a pressure threshold
Data Source
AI summary
A battery pack includes a battery, an outer enclosure housing the battery to form a battery pack, and an expandable portion extending from the outer enclosure and allowing the battery pack to expand along an X-axis of the battery pack. The expandable portion includes an inner portion, an outer portion, and a gap portion between the inner portion and the outer portion. The inner portion and the outer portion have a sealing layer to seal off an interior space and the gap portion is devoid of the sealing layer. The sealing layer allows for fluid communication between the gap portion and the interior space when a pressure exerted on the sealing layer exceeds a pressure threshold. The expandable portion includes folds allowing the expandable portion to fold toward the battery pack in an initial folded configuration and expand away from the battery pack in an at least partially unfolded configuration.