Battery Module Dual-Case Assembly for PCB Isolation
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Solution Overview
Problem
Conventional battery modules face issues with increased volume and weight due to anchoring devices, which also lead to a risk of electrical short circuits between the printed circuit board (PCB) and the battery module due to heat generation during charging and discharging.
Innovation Solution
A battery module assembly that eliminates the need for additional anchoring devices by using a dual-case structure with separate inner spaces for the battery pack and PCB, preventing direct contact and reducing thermal interference, while incorporating support portions to maintain the battery cells' arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If an anchoring device is used to fix the battery pack, then the alignment and stability of battery cells are improved, but the volume and weight of the battery module increase
Solution Approach 1:
The anchoring function is merged into the case structure itself. The lower case includes support portions that directly contact and fix the battery pack, eliminating the need for separate anchoring devices. This integration maintains alignment stability while reducing overall module volume and weight.
Solution Approach 2:
The lower case serves multiple functions: it provides structural support, accommodates the battery pack, and simultaneously acts as the anchoring mechanism through its support portions. This multi-functionality eliminates the need for dedicated anchoring components, reducing volume and weight while maintaining stability.
2Stability of the object's composition
If an anchoring device is used to fix the battery pack, then the alignment and stability of battery cells are improved, but the weight of the battery module increases
Solution Approach 1:
The anchoring function is merged into the case structure itself. The lower case includes support portions that directly contact and fix the battery pack, eliminating the need for separate anchoring devices. This integration maintains alignment stability while reducing overall module volume and weight.
Solution Approach 2:
The lower case serves multiple functions: it provides structural support, accommodates the battery pack, and simultaneously acts as the anchoring mechanism through its support portions. This multi-functionality eliminates the need for dedicated anchoring components, reducing volume and weight while maintaining stability.
3Device complexity
If the battery pack and PCB are directly contacted, then the assembly is simplified, but the risk of electrical short circuit increases due to heat generation
Solution Approach 1:
The internal space of the case is segmented into separate first and second inner spaces. The battery pack is accommodated in the first inner space while the PCB is placed in the second inner space, physically isolating them to prevent direct contact and eliminate short circuit risks from thermal expansion or heat generation.
Solution Approach 2:
The case structure itself acts as an intermediary barrier between the battery pack and PCB. By providing separate accommodated spaces within the case, it prevents direct contact while maintaining overall assembly simplicity, thus ensuring electrical safety without significantly increasing complexity.
4Reliability
If separate inner spaces are formed for battery pack and PCB, then the risk of electrical short circuit is reduced, but the device complexity increases
Solution Approach 1:
The spatial separation function is merged into the case structure design. The lower case is formed with integrated first and second inner spaces that naturally accommodate and separate the battery pack and PCB, eliminating the need for additional partitioning components or complex assembly procedures.
Solution Approach 2:
The case structure serves multiple functions: it provides mechanical protection, defines separate functional zones for battery and electronics, and maintains thermal separation. This multi-functionality achieves electrical safety without proportionally increasing structural complexity.
Data Source
AI summary
A battery module assembly includes: a battery pack having a plurality of battery cells; a lower case having an inner space accommodating at least a portion of the battery pack; an upper case having an inner space accommodating the remaining portion of the battery pack that is not accommodated in the lower case, and coupled to the lower case; and at least one lower support portion formed to protrude from an inner surface of the lower case and assist in fixing the battery pack to the lower case.