Battery Pack Circuit Module Support for Impact Protection
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Solution Overview
Problem
Battery packs face damage from external impacts and foreign matter ingress, which can compromise the reliability and operational performance of the protecting circuit module and safety devices like thermal fuses or PTCs.
Innovation Solution
A battery pack design featuring a protecting circuit module support part between the top case and the module, which can be made of materials like foam, rubber, or glue, to absorb external forces and maintain the safety device's proximity to the top case for effective heat transfer, thereby preventing damage and enhancing operational performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protecting circuit module is directly mounted on the battery pack without a support part, then the device complexity is reduced, but the reliability of the protecting circuit module deteriorates due to vulnerability from external impacts
Solution Approach 1:
A protecting circuit module support part is introduced as an intermediary element between the top case and the protecting circuit module. This support part acts as a mediator that provides mechanical protection and stable mounting while isolating the sensitive electronic components from direct exposure to external impacts, thereby resolving the contradiction between reliability improvement and structural simplicity.
Solution Approach 2:
The support part is designed with cushioning properties (using materials like foam, rubber, or glue) to provide beforehand protection against external impacts. This prior cushioning mechanism absorbs and distributes impact forces before they reach the protecting circuit module, preventing damage while maintaining a relatively simple overall structure.
2Reliability
If a protecting circuit module support part is added between the top case and the module, then the reliability is improved by preventing impact damage, but the device complexity increases
Solution Approach 1:
The support part is designed to perform multiple functions simultaneously: it provides mechanical support for mounting the protecting circuit module, cushions against external impacts, prevents foreign matter ingress, and facilitates heat transfer from the battery cell to the safety device. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity while achieving comprehensive protection.
Solution Approach 2:
The support part merges several protective functions into a single integrated component. Instead of using separate elements for mounting, cushioning, sealing, and thermal management, the design combines these functions into one support structure, thus improving reliability without proportionally increasing the number of components.
3Reliability
If the safety device is positioned away from the top case, then the device complexity is reduced, but the operational performance deteriorates due to ineffective heat transfer from overheated cells
Solution Approach 1:
The support part is designed with local quality variations to optimize heat transfer in specific regions. The portion of the support part contacting or adjacent to the battery cell is configured to have high thermal conductivity properties, creating a localized thermal pathway that efficiently transfers heat from the cell to the safety device without requiring complex overall structural changes.
4Ease of manufacture
If the protecting circuit module is exposed without a support part, then the ease of manufacture is improved, but the object-affected harmful factors increase due to foreign matter ingress
Solution Approach 1:
The support part functions as a protective shell or barrier that encloses or shields the protecting circuit module from foreign matter ingress. This flexible protective structure maintains ease of manufacture through simple integration while effectively preventing harmful factors like dust, moisture, and other contaminants from reaching the electronic components.
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 solution effectively protects the protecting circuit module from external impacts, prevents foreign matter ingress, and improves the operational performance of safety devices by ensuring effective heat transfer, thus enhancing the reliability and stability of the battery pack.
Implementation Method 1
the protecting circuit module support part allows a surface on which a safety device, such as a thermal fuse or positive temperature coefficient (PTC), is formed to be adhered more closely to a top case, so that it is possible to improve the operational performance of the safety device
Implementation Method 2
when a bare cell is abnormally overheated, the heat of the bare cell is more effectively transferred to the safety device, thereby improving the operational performance of the safety device
Data Source
AI summary
A battery pack includes a pouch-type bare cell, a protecting circuit module, a top case and a protecting circuit module support part. The pouch-type bare cell has a sealing region positioned in an extraction direction of an electrode lead. The protecting circuit module is positioned in the sealing region and connected to the electrode lead. The top case surrounds the protecting circuit module. The protecting circuit module support part is provided between the top case and the protecting circuit module. Accordingly, the protecting circuit module support part is formed between the top case and the protecting circuit module, so that it is possible to prevent a component mounted on the protecting circuit module from being damaged by an external impact and to prevent the inflow of a foreign matter from the outside of the battery pack, thereby improving the reliability and safety of the battery pack.