Battery Module LED Light Diffusion via Cover Plate Window
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Solution Overview
Problem
Existing battery modules with LED elements for displaying operating states face issues with optical loss and light diffusion due to straight light emission, requiring additional manufacturing processes and components, which complicates manufacturing and affects the structural stability and aesthetics.
Innovation Solution
A battery module design featuring a cover plate with a window for light transmission and a light-transmissive LED cover that diffuses light emitted from the LED element, ensuring easy visibility and complete shielding, while simplifying manufacturing processes and enhancing structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If additional components such as diffuser films or separate lamp structures are used to diffuse LED light, then light diffusion improves, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent integrates the light diffusing function directly into the LED element structure by forming a convex lens on the light-emitting surface of the LED chip. This merging of the diffuser function into the LED itself eliminates the need for separate diffuser films or additional lamp structures, thereby improving light diffusion while reducing device complexity and manufacturing complexity
Solution Approach 2:
The patent introduces a convex lens as an intermediary optical element formed on the LED chip surface. This lens acts as a mediator that transforms the straight light emission from the LED into diffused light, achieving the desired light diffusion effect without requiring additional separate components, thus resolving the contradiction between light diffusion and device complexity
2Illumination intensity
If additional manufacturing processes are implemented to treat LED elements with diffuser films or fabricate separate lamps, then light diffusion improves, but productivity decreases
Solution Approach 1:
The light diffusing function is merged into the LED manufacturing process itself by forming a convex lens directly on the LED chip during fabrication. This integration eliminates the need for separate post-processing steps such as applying diffuser films or assembling separate lamp structures, thereby achieving light diffusion while maintaining high manufacturing efficiency and productivity
Solution Approach 2:
The convex lens structure is formed on the LED chip during the initial fabrication process rather than as a subsequent addition. This preliminary action of integrating the diffuser function into the base LED manufacturing process eliminates the need for additional manufacturing steps, thereby improving productivity while achieving the desired light diffusion effect
3Ease of manufacture
If the protective circuit board is completely exposed, then manufacturing simplicity improves, but structural stability and aesthetics deteriorate
Solution Approach 1:
The cover plate is segmented to include a specific window portion that selectively exposes only the LED element while covering other components of the protective circuit board. This segmentation approach provides structural stability and aesthetic improvement while maintaining manufacturing simplicity, as the window is designed to match the LED element position and size
Solution Approach 2:
The cover plate is designed with a window at the specific location where the LED element is positioned, providing local transparency only where needed for light emission. This local quality approach maintains structural stability and aesthetics by covering most of the circuit board while allowing LED light to pass through, without requiring complete exposure of the board
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 solution effectively diffuses light from the LED element, making it easier to read, provides a complete shielding function, and achieves a compact, structurally stable battery module with simplified manufacturing, suitable for various applications requiring small size and high safety.
Implementation Method 1
a light-transmissive LED cover installed at an inner side of the cover plate to correspond to the window of the cover plate in order to emit light emitted from the LED element
Data Source
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AI summary
Disclosed is a battery module including an LED element on a PCB. More particularly, the battery module including at least two battery cells includes a protective circuit board installed at a side surface of the battery module and electrically connected to the battery module, at least one LED element installed on the protective circuit board and displaying changes in operating states of the battery cells, a cover plate provided with a window for light transmission of the LED element and installed at a side surface of the battery module so as to surround the protective circuit board, and a light-transmissive LED cover installed at an inner side of the cover plate to correspond to the window of the cover plate in order to emit light emitted from the LED element.