Battery Pack Frame Protrusions for Secure Cell Coupling
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Solution Overview
Problem
Existing battery packs face challenges in securely integrating a protection circuit module with a bare cell, leading to potential gaps and reduced coupling force, which can affect the stability and efficiency of the battery pack.
Innovation Solution
A battery pack design featuring a frame with protrusion parts that are specifically coupled to the short side surfaces of the bare cell, eliminating gaps and enhancing the coupling force between the frame, circuit module, and bare cell, while also incorporating an insulating adhesion member to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional frame structure is used without protrusion parts, then the frame structure is simple and easy to manufacture, but the coupling force between the frame and bare cell is insufficient, leading to gaps and reduced stability
Solution Approach 1:
The frame is divided into multiple functional regions including protrusion parts that extend into the battery pack interior. These protrusion parts are segmented structures that specifically engage with the bare cell to provide enhanced coupling force while maintaining overall frame integrity
Solution Approach 2:
The frame design adds a third dimension by incorporating protrusion parts that extend inward from the frame's outer surface. This dimensional addition creates engagement points that increase coupling force without requiring a completely redesign of the frame structure
2Reliability
If the frame covers all surfaces of the bare cell, then the protection and stability are improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The frame provides differential protection by concentrating structural enhancements (protrusion parts) at specific locations where coupling force is needed, rather than uniformly thickening the entire frame. This localized approach improves reliability at critical interfaces while maintaining manufacturing efficiency
3Strength
If the protrusion parts are made with greater thickness, then the coupling force and structural strength are enhanced, but the material usage and manufacturing complexity increase
Solution Approach 1:
The protrusion parts are designed with selective thickness enhancement only at the engagement regions where maximum coupling force is required. The rest of the frame maintains standard thickness, providing sufficient strength while minimizing material consumption
Data Source
AI summary
A battery pack including a bare cell, the bare cell including a first surface, a second surface, a pair of short side surfaces, and a pair of long side surfaces; a circuit module on the first surface of the bare cell, the circuit module being electrically connected to the bare cell; and a frame covering a portion of the bare cell including the circuit module thereon, wherein the frame has a protrusion part at interior portions of side surfaces thereof, the protrusion part being coupled to the short side surfaces of the bare cell.