Zigzag Battery Cell Stack for Shock and Swelling Control
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Solution Overview
Problem
Existing battery packs face challenges in maintaining compactness and reliability when dropped, particularly when multiple cells are connected, due to issues with shock absorption and swelling, which can lead to increased volume and reduced efficiency.
Innovation Solution
A battery pack design featuring a tape unit with integrated adhesive parts of varying materials and shapes, including hard and compressible components, allows for alternate arrangement of battery cells and zigzag folding, ensuring shock absorption and swelling management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are connected to increase output voltage or current, then the power capacity is improved, but the volume and weight of the battery pack increase
Solution Approach 1:
The patent transitions from a conventional linear arrangement of battery cells to a three-dimensional stacked configuration. Multiple battery cells are arranged in layers and stacked vertically, utilizing the vertical dimension to increase power capacity without proportionally increasing the horizontal footprint of the battery pack.
Solution Approach 2:
The patent implements a nested structure where battery cells are arranged in compact stacks with support ribs and adhesive layers integrated within the same spatial envelope. The support ribs are positioned between battery cells, and adhesive layers are applied in multiple tiers, creating a densely packed nested configuration that maximizes power density.
2Power
If multiple battery cells are connected to increase output voltage or current, then the power capacity is improved, but the weight of the battery pack increases
Solution Approach 1:
The patent transitions from a conventional linear arrangement of battery cells to a three-dimensional stacked configuration. Multiple battery cells are arranged in layers and stacked vertically, utilizing the vertical dimension to increase power capacity without proportionally increasing the horizontal footprint of the battery pack.
Solution Approach 2:
The patent implements a nested structure where battery cells are arranged in compact stacks with support ribs and adhesive layers integrated within the same spatial envelope. The support ribs are positioned between battery cells, and adhesive layers are applied in multiple tiers, creating a densely packed nested configuration that maximizes power density.
3Volume of moving object
If battery cells are arranged in a compact configuration, then the volume is reduced, but the reliability under impact decreases
Solution Approach 1:
The patent incorporates adhesive layers between stacked battery cells and support ribs that provide structural reinforcement. These adhesive layers are applied in advance during manufacturing, creating a pre-bonded structure that distributes impact forces across multiple bonding interfaces, thereby cushioning against shock and vibration before they can cause damage.
Solution Approach 2:
The patent uses a composite structure combining battery cells, adhesive materials, and support ribs. The adhesive layers serve as bonding agents that also provide shock absorption, while the support ribs add structural rigidity. This composite configuration maintains compact volume while enhancing impact resistance through the synergistic combination of different materials.
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 the reliability and compactness of battery packs by effectively absorbing shocks and swelling, maintaining a stable structure even under impact, while improving production efficiency through integrated adhesive application.
Implementation Method 1
a third adhesive part including a compressible member
Implementation Method 2
a second layer comprising a plurality of adhesive parts attached to one surface of the first layer
Implementation Method 3
the tape unit is folded in a zigzag manner to form a battery cell stack
Implementation Method 4
The design enhances the reliability and compactness of battery packs by effectively absorbing shocks
Data Source
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.