Thin Battery Vibration Stability via Elastic Spacer
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Solution Overview
Problem
Existing secondary batteries with laminated film outer cover members lack robustness and stability against vibrations, such as those from motor vehicles, due to inadequate fixing and sealing mechanisms.
Innovation Solution
A thin battery design incorporating a battery body with a laminated film outer cover member, spacers, and elastic resin portions to stabilize the battery against external forces, utilizing a three-layer structure with a resin layer, metal layer, and additional insulation for enhanced mechanical strength and heat sealing, along with elastic resin portions for buffering external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic frame members are fixed to outer peripheral portions of the outer cover member, then mechanical strength and sealing strength are increased, but robustness against vibration is insufficient
Solution Approach 1:
The patent introduces an elastic body that acts as a cushioning element between the battery body and the frame member. This elastic body absorbs vibration energy before it can damage the battery, providing beforehand cushioning against vibrational forces. The elastic body is specifically positioned to intercept and dampen vibrations from the motor vehicle environment, resolving the contradiction between maintaining mechanical strength and achieving vibration robustness.
Solution Approach 2:
The patent employs a composite structure combining rigid frame members for mechanical strength with elastic cushioning material for vibration absorption. This composite approach integrates two materials with complementary properties: the rigid plastic frame provides structural support and sealing, while the elastic body provides vibration damping. Together, they create a system that simultaneously achieves both mechanical strength and vibration robustness.
2Ease of manufacture
If outer sealing part is crammed into cramping grooves, then coupling is achieved, but fixing stability under vibration is insufficient
Solution Approach 1:
The elastic body serves as an intermediary element between the battery body and the frame member's cramping groove structure. Instead of directly coupling the battery body to the rigid frame, the elastic body mediates the connection, providing both mechanical coupling and vibration isolation. This intermediary approach maintains the ease of manufacture of the cramping groove structure while dramatically improving fixing stability under vibrational conditions.
3Volume of moving object
If thin battery design is used, then size is reduced, but mechanical integrity under external force is compromised
Solution Approach 1:
The patent utilizes the thin battery design with laminated film outer cover members while introducing an elastic body that acts as a flexible protective shell. This elastic body surrounds and protects the thin battery structure from external forces, allowing the battery to maintain its compact thin profile while gaining enhanced mechanical integrity. The flexible elastic material conforms to the thin battery shape while providing robust protection against vibration and external impacts.
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 provides stable fixing and robustness against vibrations by distributing and buffering external forces, reducing the risk of short circuits and leakage, while maintaining mechanical integrity and reducing production costs through insert molding.
Implementation Method 1
an elastic body through which the battery body and the spacer are connected... the elastic body is forced to generate a buffer power against the external force
Data Source
AI summary
Within outer cover member 111 of laminated film including resin layer 111c, there is installed electricity generating element 112 thereby to constitute battery body 11, peripheral portion 113 of the outer cover member being sealed. Spacer 12 is provided which has fixing portion 121 by which the battery body is fixed to predetermined position, the spacer being arranged between outer peripheral portion of the battery body and outer peripheral portion of another battery body put on the battery body. In range H1 that includes an overlapped portion 14 between the outer peripheral portion and the spacer and is provided at least around the fixing portion of the outer peripheral portion, there is provided elastic resin portion 13 produced through insert molding of elastic resin. This thin battery exhibits satisfied stability in set condition against vibration of motor vehicle. This thin battery exhibits satisfied fixing stability against vehicle vibration.