Battery Pack Cell-to-PCB Adhesive Structure for Stable Sensing
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Solution Overview
Problem
Existing battery pack designs face challenges in efficiently connecting and securing battery cells to a circuit board while maintaining reliable electrical connections and thermal management, leading to potential disconnections and instability.
Innovation Solution
A battery pack design featuring a cell holder with assembly ribs and hollow protrusions, along with a photocurable adhesive that covers exposed surfaces of the cell holder, circuit board, and battery cells, creating a multilevel structure for secure mechanical and electrical connections, and using measurement members to connect electrodes to the circuit board, ensuring stable voltage measurement and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are connected to the circuit board using measurement members, then electrical connections are established, but disconnections and instability may occur
Solution Approach 1:
The patent combines multiple functions into the adhesive member: it provides mechanical bonding to prevent disconnection, electrical insulation to protect measurement signals, and structural support for the measurement members. This integration of bonding, insulation, and support functions into a single component resolves the contradiction by ensuring both connection reliability and stability simultaneously
Solution Approach 2:
The adhesive member acts as an intermediary between the battery cells and the circuit board, providing a stable interface that maintains electrical connections while preventing direct contact that could cause short circuits. This mediator approach ensures both reliable electrical connection and structural stability
2Reliability
If a photocurable adhesive is used to cover the measurement members, then mechanical bonding and insulation are provided, but UV light transmission may be blocked
Solution Approach 1:
The adhesive member is designed with non-uniform optical properties: it is substantially transparent to UV light at the first end portion where curing is needed, while being opaque or translucent at other portions where insulation and protection are prioritized. This local differentiation of optical quality resolves the contradiction between bonding reliability and UV transmission
Solution Approach 2:
The adhesive member is segmented into different functional zones along its length: the first end portion near the battery cell is designed for UV transmission and bonding, while other portions provide insulation and protection. This segmentation allows simultaneous achievement of reliable bonding and UV light transmission
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 design enhances the reliability of electrical connections, prevents disconnections, and improves thermal management by securely fixing the cell holder, circuit board, and battery cells together, ensuring stable operation and efficient heat dissipation.
Implementation Method 1
a photocurable adhesive surrounding the measurement members, wherein the first end portions of the plurality of battery cells, the first surface of the cell holder, and the first surface of the circuit board are arranged in a stepped manner at least partially exposed to an outside of the circuit board in the length direction of the plurality of battery cells and are at least partially covered by the photocurable adhesive
Data Source
AI summary
A battery pack including battery cells including a first end portion and a second end portion in a length direction thereof; a cell holder having a first surface through which portions of the first end portions are exposed in the length direction; a circuit board having a first surface through which the portions of the first end portions and a portion of the first surface of the cell holder are exposed; measurement members connecting the battery cells to the circuit board; and a photocurable adhesive surrounding the measurement members, wherein the first end portions, the first surface of the cell holder, and the first surface of the circuit board are arranged in a stepped manner at least partially exposed to an outside of the circuit board in the length direction of the battery cells and are at least partially covered by the photocurable adhesive.