Battery Pack Barrier Rib Design for Circuit Module Alignment
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Solution Overview
Problem
The existing battery pack assembly process is prone to errors and damage due to the spacing of protection circuit modules and battery cells, which can lead to interference and incorrect placement during assembly.
Innovation Solution
A battery pack design featuring a first case with dividing and auxiliary barrier ribs that support the protection circuit module, ensuring proper alignment and easy assembly by maintaining the height of supporting ribs equal to or greater than the barrier ribs, with rounded top edges guiding the circuit substrate for foolproof insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protection circuit module and battery cells are spaced apart to prevent damage, then reliability is improved, but assembly precision deteriorates due to interference and incorrect placement
Solution Approach 1:
Support ribs are introduced as intermediary structures between the barrier rib and the protection circuit module. These supporting ribs provide a dedicated interface for mounting the circuit substrate, ensuring precise positioning while maintaining the necessary spacing for protection. The supporting ribs act as mediators that simultaneously achieve both damage prevention through spacing and assembly precision through structured support.
Solution Approach 2:
The barrier rib structure is segmented into two functional parts: the main barrier rib that provides spacing for protection, and the supporting ribs that provide mounting surfaces for precision assembly. This segmentation allows each part to fulfill its specific function optimally - the barrier rib ensures reliability through spacing, while the supporting ribs ensure manufacturing precision through structured support interfaces.
2Ease of operation
If supporting ribs are added to support the protection circuit module, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The supporting ribs are merged with the existing barrier rib structure, forming an integrated component rather than separate additions. The supporting ribs extend from the barrier rib, combining the spacing function and the support function into a single unified structure. This merging approach improves ease of assembly while minimizing the increase in device complexity by utilizing the existing structural framework.
Solution Approach 2:
The barrier rib structure is designed to serve multiple functions simultaneously: it provides spacing for protection, structural support for the protection circuit module, and mounting surfaces for the circuit substrate. By making the barrier rib multi-functional through the addition of supporting ribs, the design achieves improved ease of assembly without requiring entirely separate components for each function.
Data Source
AI summary
A design for a battery pack that provides for a foolproof and easy assembly process, especially during when the protection circuit module is inserted into and combined with the battery case. The protection circuit module includes a circuit substrate with driving circuits arranged on both sides thereof. This circuit substrate is inserted between a first barrier rib of the battery case and a second barrier rib and arranged in parallel thereto. Supporting barrier ribs extending orthogonal from the barrier ribs towards the circuit substrate have a rounded top edge to guide the circuit substrate into the proper location in the battery case. The height of these supporting barrier ribs are formed at least as tall as the barrier ribs to prevent the circuit substrate or the driving circuits from contacting the barrier ribs during the insertion process.