Battery Pack Adhesion Member With Mesh Insulation
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Solution Overview
Problem
Existing rechargeable battery packs face challenges in reinforcing adhesion strength between unit cells in parallel, between the protection circuit module (PCM) and the terrace portion, and in improving insulation performance between these components.
Innovation Solution
A rechargeable battery pack design featuring a pouch with a terrace portion and a vertical portion, where the PCM is electrically connected and attached using an adhesion member with a separation portion that fits into a concave groove, providing enhanced adhesion and insulation through a mesh-structured double-sided adhesive tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If unit cells are disposed in parallel to form a rechargeable battery pack, then the battery pack can provide required power and capacity, but the adhesion strength between adjacent unit cells deteriorates
Solution Approach 1:
An adhesion member is introduced as an intermediary element between adjacent unit cells to provide mechanical bonding. The adhesion member includes a separation portion that fits into a concave groove formed between the unit cells, creating a dedicated attachment interface that reinforces the bond between parallel-disposed cells while allowing electrical connections to pass through.
Solution Approach 2:
The adhesion member is segmented into different functional portions: a connection portion that bonds to the unit cells and a separation portion that fits into the concave groove. This segmentation allows the adhesion member to simultaneously provide strong mechanical attachment while accommodating the electrical lead tabs and maintaining proper spacing between cells.
2Reliability
If a protection circuit module (PCM) is attached to the terrace portion to protect unit cells, then protection function is provided, but the adhesion strength between PCM and terrace portion deteriorates
Solution Approach 1:
The adhesion member serves as an intermediary between the PCM and the terrace portion, providing mechanical attachment while accommodating the vertical portion. The separation portion of the adhesion member fits around the vertical portion, creating a secure interface that bonds the PCM to the terrace portion without being disrupted by the protruding vertical structure.
Solution Approach 2:
The separation portion of the adhesion member is nested around the vertical portion of the pouch, with the concave groove providing a recess that accommodates the vertical portion. This nesting arrangement allows the adhesion member to maintain continuous contact with both the PCM and the terrace portion while adapting to the three-dimensional geometry created by the vertical portion.
3Reliability
If a PCM is attached to the terrace portion to protect unit cells, then protection function is provided, but insulation performance between PCM and terrace portion deteriorates
Solution Approach 1:
The adhesion member acts as an intermediary layer between the conductive PCM and the pouch structure, providing electrical insulation. By positioning the adhesion member between the PCM and the terrace portion, and having the separation portion fit around the vertical portion, the adhesion member creates an insulating barrier that prevents direct electrical contact while maintaining mechanical attachment.
4Strength
If an adhesion member is used to connect PCM and terrace portion, then adhesion strength is improved, but interference between adhesion member and vertical portion increases
Solution Approach 1:
The adhesion member has different local properties: the connection portion provides strong bonding capability, while the separation portion provides a fit-around geometry that accommodates the vertical portion. This local differentiation allows the adhesion member to provide strong attachment exactly where needed while adapting to the presence of the vertical portion without creating interference.
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
This design enhances the close adhesion strength between unit cells, improves insulation performance, and maintains stability by minimizing interference between the adhesion member and vertical portions, thereby ensuring effective protection against overcharge, over-discharge, and short circuits.
Implementation Method 1
an adhesion member connecting the PCM and the terrace portion of the pouch
Implementation Method 2
The adhesion member may include a mesh portion between first and second adhesive layers, the first and second adhesive layers being connected to each other through air gaps in the mesh portion
Implementation Method 3
The pouch may include a first casing material and a second casing material that are thermally fusion-bonded to house electrode assemblies
Data Source
AI summary
A rechargeable battery pack includes a plurality of unit cells adjacent to each other along a first direction in a pouch, the pouch having a terrace portion at one side surface, and a vertical portion on and perpendicular to the terrace portion, a protection circuit module (PCM) electrically connected to the unit cells, the PCM including a concave groove, and the vertical portion of the pouch fitting into the concave groove, and an adhesion member connecting the PCM and the terrace portion of the pouch, the adhesion member including a separation portion configured to concavely separate and fit the vertical portion of the pouch.