Battery Pack Protection Circuit Coating Contour Control
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Solution Overview
Problem
The existing design of secondary battery packs faces challenges in maintaining the shape and height of the protection circuit module during the application of a coating solution, leading to potential contamination and difficulty in forming the desired shape, especially as substrates become thinner, increasing the risk of damage from impacts.
Innovation Solution
A battery pack design that includes a substrate with specific mounting areas for components and a coating area with protruding portions made of the same material as the substrate, which supports the coating solution and maintains its shape, preventing overflow and contamination by forming a closed contour with a constant height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a coating solution is applied to the protection circuit module without a fixing frame, then the application process is simpler, but the shape and height of the coating solution cannot be managed, leading to contamination
Solution Approach 1:
A fixing frame is introduced as an intermediary structure between the substrate and the coating solution. The fixing frame includes protruding portions that define the coating area and constrain the coating solution within specific boundaries, enabling precise control of the coating solution's shape and height while maintaining a relatively simple application process
Solution Approach 2:
The fixing frame is divided into multiple protruding portions that correspond to different coating areas on the substrate. Each protruding portion independently defines a specific coating region, allowing segmented control of the coating solution distribution across different areas of the protection circuit module
2Volume of moving object
If the substrate is made thinner to reduce size, then the battery pack becomes more compact, but the substrate becomes more susceptible to damage from impacts
Solution Approach 1:
The fixing frame is constructed from a material that differs from the substrate material, creating a composite structure. The fixing frame provides enhanced mechanical strength and impact resistance to the otherwise thin substrate, while still allowing the substrate to maintain its reduced thickness for compactness
Solution Approach 2:
The fixing frame acts as a protective structure that is in place before the coating solution is applied and before potential impacts occur. It provides pre-established mechanical support and cushioning to the thin substrate, preventing damage from impacts that would otherwise affect the vulnerable thin substrate
3Adaptability or versatility
If protruding portions are made from different material than the substrate, then mounting flexibility increases, but compatibility and structural integrity decrease
Solution Approach 1:
The protruding portions are made from the same material as the substrate, creating a homogeneous structure. This ensures material compatibility, structural integrity, and reliable electrical connections while still providing the necessary mounting flexibility through the geometric design of the protruding portions rather than material diversity
Data Source
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AI summary
A battery pack (10) includes a case (120), a battery cell (110) accommodated in the case (120), and a protection circuit module (130) connected to the battery cell (110), wherein the protection circuit module (130) includes a substrate (131), at least one component mounting area (134) on the substrate (131) and comprising a plurality of components (1341), and at least one coating area (133) on the substrate (131) at least in part corresponding to the at least one component mounting area (134) and comprising at least one protruding portion (1331) supporting a coating solution (C) within the at least one coating area (133), and at least a portion of the at least one protruding portion (1331) includes a same material as that of the substrate (131) and is mounted on the substrate (131).