Battery Pack Protection Circuit Coating Shape 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 module to a desired shape, especially as substrates become thinner and more prone to damage.
Innovation Solution
A battery pack design that includes a substrate with specific mounting areas for components and coating areas, featuring protruding portions made of the same material as the substrate to support the coating solution, which helps maintain the shape and prevent overflow, ensuring proper assembly and protection of the module.
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 properly managed, leading to contamination and overflow
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 extend into the coating area to physically constrain the coating solution, maintaining its shape and height during application. This mediator enables precise coating without requiring complex application processes.
Solution Approach 2:
The coating area is segmented into multiple regions by dividing the protruding portions into several segments. This segmentation allows the coating solution to be applied in a controlled manner, with each segment managing a specific portion of the coating, thereby preventing overflow while maintaining manufacturing simplicity.
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 prone to damage and cannot properly support the coating solution
Solution Approach 1:
The support structure transitions from a two-dimensional flat substrate to a three-dimensional structure with protruding portions extending vertically into the coating area. This dimensional change allows the thin substrate to provide adequate support for the coating solution by utilizing vertical space, thereby maintaining substrate thinness while ensuring structural integrity.
3Manufacturing precision
If protruding portions are added to the substrate to support the coating solution, then the shape and height of the coating solution are properly managed, but the substrate structure becomes more complex
Solution Approach 1:
The fixing frame is merged with the substrate as an integrated structure, where the protruding portions are formed as part of the substrate itself rather than as separate components. This merging reduces device complexity by eliminating the need for additional fixing frame parts while maintaining the precision control of the coating solution.
Data Source
AI summary
A battery pack includes a case, a battery cell accommodated in the case, and a protection circuit module connected to the battery cell, wherein the protection circuit module includes a substrate, at least one component mounting area on the substrate and comprising a plurality of components, and at least one coating area on the substrate at least in part corresponding to the at least one component mounting area and comprising at least one protruding portion supporting a coating solution within the at least one coating area, and at least a portion of the at least one protruding portion includes a same material as that of the substrate and is mounted on the substrate.