Pouch Cell Battery Pack Frame Adhesive for Impact and Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs using pouch type cells face challenges in protecting against external impacts due to the limitations of cushion materials, which either fail to absorb impact forces or apply excessive loads, and are vulnerable to thermal expansion.
Innovation Solution
A battery pack design featuring an adhesive layer arranged in a frame shape between the pouch type cell and the battery case, with a buffer material and double-sided tape to absorb impact and prevent pressure contact, and an adhesive layer with specific tensile stress and width dimensions to manage thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cushion material is used to protect battery from impact, then impact protection is improved, but the battery may be vulnerable to thermal expansion and the cushion material may apply excessive loads
Solution Approach 1:
The protection system is divided into multiple functional components: adhesive layers positioned at specific locations to provide impact absorption and thermal expansion accommodation, and buffer material placed only in specific regions (not covering the entire battery surface). This segmentation allows each component to perform its specific function without interfering with others, solving both impact protection and thermal expansion vulnerability.
Solution Approach 2:
The adhesive layers are applied in specific locations (frame shape along outer edges) rather than uniformly across the entire battery surface. This local application provides impact protection where needed while leaving other areas free for thermal expansion, thus resolving the contradiction between impact protection and thermal expansion vulnerability.
2Strength
If double-sided tape is used to bond battery to battery case, then bonding strength is improved, but quality improvement is limited
Solution Approach 1:
The adhesive properties are optimized by selecting adhesive materials with specific tensile stress characteristics (0.01 to 0.05 N/mm) and controlling the adhesive layer thickness (0.1 to 0.5 mm). These parameter changes provide sufficient bonding strength while maintaining quality improvement, overcoming the limitations of conventional double-sided tape.
Solution Approach 2:
The bonding system uses composite construction combining adhesive layers with specific tensile stress properties and buffer material with elastic modulus of 0.1 to 10 MPa. This composite approach provides both strong bonding and quality improvement by distributing stresses appropriately and accommodating thermal expansion.
3Object-affected harmful factors
If adhesive layer with frame shape is used, then impact force absorption is improved, but manufacturing precision requirements increase
Solution Approach 1:
The adhesive layers are positioned in advance during the battery pack assembly process, with predetermined locations and dimensions. The frame-shaped adhesive layers are applied along the outer edges before battery installation, ensuring proper positioning and reducing manufacturing precision requirements during final assembly.
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 adhesive layer effectively absorbs impact forces and prevents damage to the battery, while the buffer material and double-sided tape configuration ensures the battery is securely held without gaps, enhancing the battery pack's resistance to external impacts and thermal expansion.
Implementation Method 1
an adhesive layer that is arranged between at least one of the first plane and the second plane of the battery and an inner surface of the battery case in a shape of a frame along an outer edge of the battery
Implementation Method 2
the adhesive layer with specific tensile stress and width dimensions to manage thermal expansion
Data Source
AI summary
A battery pack includes: a battery case; a battery that is housed in the battery case and configured of a pouch type cell having a first plane and a second plane disposed on an opposite side of the first plane; and an adhesive layer that is arranged between at least one of the first plane and the second plane of the battery and an inner surface of the battery case in a shape of a frame along an outer edge of the battery.