Battery Pack Coupler Elastic Region Impact Resistance
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Solution Overview
Problem
The increase in electrical resistance between the bare cell and the protection circuit in battery packs due to external impact, which reduces charge/discharge efficiency and stability, is not effectively addressed by existing technologies.
Innovation Solution
A battery pack design featuring a bare cell with a coupling groove and a protection circuit electrically coupled via a coupler with an elastic region, which includes a burr prevention region and an elastic support mechanism to maintain contact resistance and coupling strength even under external impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rigid coupling structure is used to connect the bare cell and protection circuit, then assembly efficiency is improved, but contact resistance increases under external impact due to separation
Solution Approach 1:
The coupler material's elastic modulus is designed to be lower than both the bare cell and protection circuit materials, allowing the coupler to deform elastically under impact while maintaining electrical contact. This parameter change in material stiffness enables the structure to absorb impact energy without separating, preventing contact resistance increase while maintaining assembly efficiency.
Solution Approach 2:
The coupler is designed with inherent elastic deformation capability before impact occurs, creating a cushioning effect that absorbs impact energy. This beforehand cushioning prevents direct separation between the bare cell and protection circuit, maintaining stable electrical contact under external impact conditions.
2Reliability
If a flexible coupling structure is used to maintain contact under impact, then contact resistance stability is improved, but assembly complexity increases
Solution Approach 1:
Instead of using complex flexible mechanisms or multiple components, the solution changes the material parameter (elastic modulus) of the coupler itself. This single parameter change enables the rigid-looking coupler to exhibit flexible, elastic behavior under impact, maintaining contact stability without increasing structural complexity.
Solution Approach 2:
The coupler uses a composite material approach where a material with intermediate elastic modulus properties is selected, combining characteristics of both rigid and flexible materials. This allows the coupler to maintain structural integrity while providing elastic deformation capability, simplifying the overall coupling structure.
3Strength
If high-strength bonding is used to prevent separation, then coupling strength is improved, but manufacturing difficulty increases due to burr formation
Solution Approach 1:
The elastic coupler provides beforehand cushioning that prevents impact-induced separation, eliminating the need for high-strength bonding that would cause burr formation. The cushioning effect absorbs impact energy through elastic deformation, allowing for easier manufacturing without burr-related difficulties.
Solution Approach 2:
The solution replaces mechanical bonding (screws, clips, or strong adhesives) with an elastic deformation mechanism. Instead of relying on high-strength mechanical connections that create burr formation issues, the system uses elastic cushioning to maintain coupling strength, simplifying manufacturing.
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 significantly reduces contact resistance and improves coupling strength between the bare cell and the protection circuit, enhancing the reliability and assembly efficiency of the battery pack.
Implementation Method 1
the coupler includes an elastic region for elastically supporting the fastener and the bare cell
Data Source
AI summary
A battery pack includes a bare cell having a coupling groove and a protection circuit electrically coupled to the bare cell. A coupler has a first end attached to the protection circuit and a second end defining a coupling hole, the second end contacting the bare cell. A fastener is combined to the coupling groove through the coupling hole; wherein the coupler includes an elastic region for elastically supporting the fastener and the bare cell.