Battery Pack Coupling Member Material and Groove Design
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Solution Overview
Problem
Battery packs face issues with increased internal resistance and cover case separation due to external shocks, particularly because existing materials like aluminum lack sufficient mechanical strength to withstand fastening forces and external impacts.
Innovation Solution
The battery pack design incorporates a coupling member made of a material with higher mechanical strength than aluminum, such as nickel, which is coupled to the cap plate using a screw bolt and features a groove structure to securely attach the protective circuit board, preventing the cover case from separating and maintaining low internal resistance even under external shocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum is used as the coupling member material, then the battery pack is lightweight, but the mechanical strength is insufficient to withstand fastening forces and external shocks
Solution Approach 1:
The patent changes the material parameter of the coupling member from aluminum to nickel, which has higher mechanical strength and hardness. This parameter change allows the coupling member to withstand fastening forces and external shocks without deforming or breaking, resolving the strength insufficiency while accepting the associated weight increase.
Solution Approach 2:
The patent employs a composite structure where the coupling member is made of nickel material that is harder and stronger than aluminum. This material substitution creates a composite-like effect by combining the cap plate with a high-strength coupling member, achieving both structural integrity and shock resistance.
2Reliability
If a simple fixing structure is used, then the assembly is simple, but the cover case separates under external shocks
Solution Approach 1:
The patent introduces a groove structure with curved surfaces on the coupling member that engages with the cap plate. This curved groove design provides mechanical interlocking that prevents separation under external shocks, enhancing assembly reliability while adding only moderate structural complexity.
Solution Approach 2:
The patent applies a localized groove structure at the critical coupling interface between the coupling member and cap plate. This local quality enhancement provides targeted reinforcement exactly where external shocks would cause separation, improving reliability without requiring complex modifications throughout the entire structure.
Data Source
AI summary
The battery pack comprises: a bare cell including a can, wherein the can includes an opening on one side, and a cap plate sealing the opening of the can, wherein the cap plate has at least one groove formed on one surface; a circuit board including at least one lead tab. wherein the lead tab is coupled to the cap plate by a fixing body; and a coupling member coupled with the fixing body in the groove. The coupling member and the bare cell are made of different materials. Therefore, in the battery pack, the internal resistance between the bare cell and the protective circuit board does not increase, or the cover case is not separated when an external shock is applied.