Rechargeable Battery Pack With Coupling Grooves and Protrusions
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Solution Overview
Problem
Existing rechargeable battery packs for portable devices lack sufficient strength for drop tests and are not easily separable from devices, while also having a bulky design due to gaps between cases.
Innovation Solution
A rechargeable battery pack design featuring a pouch-type unit cell enclosed in a frame with a pair of cases coupled to the frame's sides, utilizing coupling grooves and protrusions to reduce thickness and enhance strength, allowing for separability and improved impact protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional battery pack structure is used, then the device can be powered, but the strength according to drop test is insufficient
Solution Approach 1:
The battery pack is divided into separate components: a battery module, a first case with a first coupling structure, and a second case with a second coupling structure. The cases can be separated from the battery module, allowing the battery to be replaced or serviced while maintaining structural strength during drop tests when assembled.
Solution Approach 2:
The coupling structures are designed to provide strong mechanical connection during normal use and drop events, while allowing for intentional separation by users or service personnel. The dynamic nature of the coupling allows the structure to adapt between being firmly connected during operation and being separable for maintenance.
2Object-affected harmful factors
If cases are added to surround the unit cell, then impact protection is improved, but the overall thickness increases due to gaps between cases
Solution Approach 1:
The first case and second case are coupled to opposite sides of the battery module with minimal gaps between them. The coupling structures merge the cases into a unified protective enclosure that surrounds the unit cell, providing impact protection while minimizing overall thickness by eliminating unnecessary spacing.
3Ease of operation
If the battery pack is designed for separability, then ease of operation is improved, but structural strength may be compromised
Solution Approach 1:
The battery pack is segmented into separable components (cases and battery module) with distinct coupling interfaces. This segmentation enables easy separation for user operation while each component maintains its structural integrity, and the coupling structures provide sufficient strength when connected.
4Length of moving object
If coupling grooves and protrusions are used to reduce thickness, then overall thickness is reduced, but manufacturing complexity increases
Solution Approach 1:
The coupling mechanism is segmented into discrete grooves and protrusions that can be independently formed on each case and the battery module. This segmentation allows for simplified manufacturing of each component while achieving the overall thickness reduction when assembled, as each part can be manufactured separately with standard processes.
Data Source
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AI summary
A rechargeable battery pack includes a frame accommodating a unit cell including a rechargeable battery; a protection circuit module electrically connected to the unit cell and in the frame; and a pair of cases coupled to opposite sides of the frame and accommodating the unit cell and the protection circuit module, and wherein the frame has coupling grooves in the sides and wherein each of the pair of cases comprises coupling protrusions, the coupling protrusions of each case being alternately coupled to the coupling grooves.