Rotatable Wing Casing Frame for Battery Pack Shock Protection
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Solution Overview
Problem
Secondary batteries are vulnerable to damage from external shocks, such as drops, due to their operational efficiency being compromised by the injection molding process of hot resin, which can cause thermal damage and reduce the manufacturing process's efficiency.
Innovation Solution
A battery pack design featuring a pouch type battery cell and a casing frame with rotatable wing portions that surround and secure the battery cell, providing improved shock resistance and easy assembly, eliminating the need for high-temperature resin injection and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If injection molding with hot resin is used to protect the battery cell from external shock, then the battery cell is protected from shock, but thermal damage occurs to the battery cell and manufacturing efficiency is reduced
Solution Approach 1:
The patent removes the harmful hot resin injection process from the battery pack manufacturing. Instead of using injection molding to fill gaps between the battery cell and frame, the design uses a precise fit structure where the battery cell directly contacts the frame, eliminating the need for thermal resin injection and avoiding thermal damage to the battery cell.
Solution Approach 2:
The patent introduces a frame structure as an intermediary element between the battery cell and the external environment. This frame provides shock protection without requiring hot resin injection, serving as a mechanical barrier that protects the battery cell from external shocks while avoiding thermal damage.
2Strength
If injection molding process is used to form the frame, then the frame can surround the battery cell, but the manufacturing process becomes complex and less efficient
Solution Approach 1:
The patent extracts the complex injection molding process from the manufacturing sequence. The frame is designed to be assembled around the battery cell without requiring hot resin injection, simplifying the manufacturing process while maintaining the protective frame structure.
Solution Approach 2:
The frame is divided into multiple segments including a body frame, a first lateral frame with hinge and wing portions, and a second lateral frame. These segmented components can be separately manufactured and then assembled around the battery cell, simplifying the overall manufacturing process while maintaining structural integrity.
3Strength
If the wing portion is made fixed to surround the battery cell, then shock resistance is improved, but assembly and disassembly become difficult
Solution Approach 1:
The patent makes the wing portion dynamic rather than fixed. The wing portion can rotate between a first position (open) for easy assembly and disassembly, and a second position (closed) for providing shock protection. This dynamic structure allows the battery pack to be easily assembled while maintaining strong shock resistance during operation.
Solution Approach 2:
The hinge portion is pre-configured to allow the wing portion to rotate into the correct position during assembly. This preliminary design of the hinge mechanism enables easy assembly without requiring complex fastening operations, while still providing strong shock resistance when the wing portion is in the closed position.
Data Source
AI summary
A battery pack and a method of manufacturing the battery pack, to include a pouch battery cell and a casing frame to accommodate and securely surround the battery cell. The casing frame may be constructed with a base frame, a first lateral frame protruding from one edge of the base frame, and a wing portion that is rotatable with respect to the base frame. The wing portion rotates from a first position where the battery cell can be inserted into the casing frame, to a second position where the battery cell is surrounded by and secured within the casing frame against damage from external forces, impulses and impacts.