Zigzag Battery Pack Assembly for Shock and Swelling Absorption
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Solution Overview
Problem
Existing battery packs face challenges in maintaining compactness and reliability when dropped, particularly due to swelling of battery cells, and production efficiency is hindered by the need for separate tape application between each cell.
Innovation Solution
A battery pack design featuring a tape unit with integrated adhesive parts of varying materials and shapes, including first and second adhesive parts for shock absorption and swelling absorption, respectively, allowing for efficient assembly and compact stacking of battery cells in a zigzag configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate tape application is used between each battery cell, then reliable shock absorption is achieved, but production efficiency decreases due to time-consuming manual assembly
Solution Approach 1:
Multiple separate adhesive tapes are merged into a single integrated tape unit that combines first adhesive parts for shock absorption, second adhesive parts for swelling absorption, and third adhesive parts for positioning. This integration allows all adhesive components to be applied simultaneously in one step, dramatically improving production efficiency while maintaining the protective functions of each individual adhesive type.
Solution Approach 2:
The tape unit serves multiple functions simultaneously: it provides shock absorption through the first adhesive parts, swelling absorption through the second adhesive parts, and positioning through the third adhesive parts. This multi-functional design eliminates the need for separate assembly steps for each function, resolving the contradiction between reliability and productivity.
2Ease of manufacture
If battery cells are arranged in a simple linear configuration, then assembly is simple, but the battery pack size becomes large and compactness is reduced
Solution Approach 1:
The battery cells are arranged in a zigzag pattern that utilizes two-dimensional space more efficiently rather than a simple linear one-dimensional arrangement. The tape unit is folded in a zigzag manner to form a battery cell stack, allowing cells to be positioned in alternating rows that interlock compactly, reducing the overall battery pack volume while maintaining assembly simplicity through the integrated tape structure.
Solution Approach 2:
The alternating arrangement of battery cells from first and second groups creates a nested-like structure where cells from different groups interlock in a compact configuration. The zigzag folding of the tape unit enables this nested arrangement, allowing the battery cells to be packed more densely without complicating the assembly process.
3Ease of manufacture
If uniform adhesive parts are used between all battery cells, then manufacturing is simple, but both shock absorption and swelling absorption requirements are not optimally met
Solution Approach 1:
Different types of adhesive parts are placed at specific locations within the tape unit: first adhesive parts with higher viscosity are positioned where shock absorption is needed, second adhesive parts with lower viscosity are positioned where swelling absorption is required, and third adhesive parts are positioned for positioning functions. This local differentiation optimizes the performance of each adhesive type for its specific function while maintaining a unified tape structure that does not significantly complicate manufacturing.
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 enhances shock and swelling absorption, maintains a compact structure, and improves production efficiency by allowing simultaneous attachment of adhesive parts to multiple cells, facilitating faster assembly.
Implementation Method 1
a first adhesive part including a first part formed to correspond to an edge of a surface of one of the battery cells and a second part formed to correspond to a central portion of a surface of one of the battery cells
Implementation Method 2
the plurality of adhesive parts includes first adhesive parts, second adhesive parts, and a third adhesive part
Data Source
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AI summary
A battery pack is provided with a tape unit and battery cells disposed on both sides of the tape unit. The battery cells include a first battery cell group disposed on a first surface of the tape unit, and a second battery cell group disposed on a second surface of the tape unit, wherein the battery cells in the first battery cell group are arranged alternately with the battery cells in the second battery cell group with respect to a direction of the tape unit. The tape unit is folded in a zigzag manner to form a battery cell stack.