Velcro Attachment Between Battery Cells for Impact Absorption
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Solution Overview
Problem
Conventional attachment members in battery modules, such as adhesives, lose strength over time and fail to maintain the stacked structure of battery cells under external impacts, particularly in large-sized modules used for electric vehicles, where long-term stability and cooling efficiency are critical.
Innovation Solution
The use of female- and male-type Velcro tapes as attachment members between battery cells, which securely attach and absorb external impacts, allowing coolant passage for improved cooling efficiency and maintaining attachment strength over long-term use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding agents or chemical bonding agents are used as attachment members, then the battery cells can be bonded together to form a stacked structure, but the attachment strength deteriorates after long-term use and the attachment layers separate under external forces
Solution Approach 1:
The patent replaces chemical bonding agents with a mechanical fastening system consisting of protrusions and recesses that interlock physically. This mechanical interlocking mechanism eliminates the degradation issues associated with adhesive bonding while providing stable, long-term attachment strength that resists external forces and shear stress.
Solution Approach 2:
The patent changes the bonding mechanism from chemical adhesion to mechanical interlocking by designing specific geometric parameters of protrusions and recesses. This parameter change enables the attachment members to maintain their fastening capability over extended service periods without the strength deterioration characteristic of adhesive bonding.
2Ease of manufacture
If attachment members are directly bonded to battery cell surfaces, then the battery cells can be connected, but the attachment layers are easily separated when external forces such as shear stress are applied
Solution Approach 1:
The patent employs thin attachment members with flexible interlocking structures that can accommodate minor misalignments and stress variations. These thin fastening elements maintain structural stability under external forces while preserving assembly simplicity, as they can be easily attached to the battery cell surfaces without complex bonding processes.
Solution Approach 2:
The attachment members are designed as composite structures combining protrusions and recesses that work together to distribute and resist external forces. This composite geometric design enhances reliability by preventing separation under shear stress while maintaining ease of manufacture through modular attachment components.
3Productivity
If conventional attachment members are used, then the battery module can be assembled, but the attachment strength is greatly reduced after long-term use and the stacked structure is not maintained
Solution Approach 1:
The patent divides the attachment system into segmented components with protrusions on one battery cell and corresponding recesses on adjacent cells. This segmentation creates multiple discrete attachment points that collectively maintain the stacked structure's stability over long-term use while allowing for efficient assembly through simple engagement of these segmented elements.
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 Velcro tape system effectively prevents battery cell sliding, maintains structural stability, and enhances cooling efficiency while ensuring consistent attachment strength, making it suitable for high-capacity and high-output applications like electric vehicles.
Implementation Method 1
attachment members, such as an adhesive bonding agent, for example, a double-side adhesive tape, or a chemical bonding agent that can be coupled due to a chemical reaction when the chemical bonding agent is bonded
Implementation Method 2
the female- and male-type Velcro (R) tapes are elastically deformed, when the external impacts are applied to the battery cells, to absorb the external impacts
Data Source
AI summary
Disclosed herein is a battery module constructed in a structure in which a plurality of plate-shaped battery cells are stacked one on another. The battery module has attachment members interposed between the battery cells to prevent the battery cells from sliding due to external impacts and also to absorb the external impacts. The battery cells are securely attached to each other by the coupling between the attachment members, such as female- and male-type Velcro tapes. Consequently, the sliding of the battery cells due to external impacts is effectively prevented. Also, the female- and male-type Velcro tapes are elastically deformed, when the external impacts are applied to the battery cells, to absorb the external impacts. In addition, it is possible for a coolant, such as air, to pass through the coupled Velcro tapes by virtue of the structural characteristics of the female- and male-type Velcro tapes. Consequently, the cooling efficiency of the battery module is improved. Furthermore, the long-term use of the female- and male-type Velcro tapes is secured without the reduction of the attachment strength thereof, and therefore, the stacked structure of the battery module is stably maintained.