Battery Pack Coupling Groove Design for Impact Resistance
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Solution Overview
Problem
Battery packs experience increased contact resistance between the bare cell and the protection circuit module due to external impacts, which reduces charging/discharging efficiency and reliability.
Innovation Solution
A battery pack design featuring coupling grooves and screws with specific dimensions and chamfered corners, along with an elastic member, to securely connect the bare cell and protection circuit module, preventing contact resistance increases during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bare cell and protection circuit module are connected using conventional methods, then the battery pack can be assembled, but the contact resistance increases due to external impacts
Solution Approach 1:
The patent applies beforehand cushioning by designing the coupling groove with a larger diameter than the coupling hole, creating a space buffer zone. This space acts as a cushion that absorbs external impacts before they can affect the electrical contact between the screw bolt and the protection circuit module, thereby preventing contact resistance increase while maintaining reliable connection.
2Reliability
If the coupling groove diameter is increased to prevent contact resistance, then impact resistance improves, but the assembly space requirement increases
Solution Approach 1:
The patent applies local quality by creating a non-uniform coupling groove structure where only specific regions have different properties. The coupling groove has a larger diameter at the opening to provide impact absorption space, while the bottom portion maintains sufficient depth for secure screw bolt engagement. This localized dimensional variation provides impact resistance without requiring uniform increase in overall groove volume.
3Reliability
If the screw bolt is tightly secured to ensure electrical connection, then contact resistance decreases, but the assembly complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the coupling function into distinct components: the coupling groove provides mechanical engagement and impact absorption, the screw bolt provides electrical connection and tightening force, and the coupling member (protection circuit module) provides both electrical functionality and structural support. This segmentation allows each component to be optimized for its specific function, achieving reliable electrical connection without excessive overall complexity.
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 maintains constant contact resistance and enhances assembly convenience, ensuring reliable operation and reduced risk of contact resistance increase under external impacts.
Implementation Method 1
at least one elastic member disposed between the cover case and the bare cell
Data Source
AI summary
A battery pack that does not increase contact resistance when an impact is applied to a bare cell and a protection circuit module. The battery pack includes: a bare cell having a surface on which at least one coupling groove is formed; a protection circuit module electrically connected to the bare cell; at least one coupling member having one end coupled to the protection circuit module and another end in which at least one coupling hole corresponding to the at least one coupling groove of the bare cell is formed, and tightly adhered to the bare cell; at least one screw bolt coupled to the at least one coupling groove through the at least one coupling hole; and at least one space formed in an opening part of the at least one coupling groove, having a diameter greater than that of the coupling groove. Therefore, the battery pack does not increase the contact resistance between the bare cell and the protection circuit module against an external impact.