Battery Pack Inner Outer Frame Assembly
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Solution Overview
Problem
The existing manufacturing processes for battery packs are complex and inefficient, particularly in ensuring proper shape matching and assembly of components, which hinders productivity and compatibility with external devices.
Innovation Solution
A battery pack design featuring a bare cell with specific side and plane portions, a protection circuit module, a U-shaped inner frame, and a rectangular outer frame, connected via interengaging protruding and groove portions, along with a taping member, to simplify assembly and enhance shape matching, using materials like polycarbonate and ABS for frames and insulating tape for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional battery pack assembly methods are used, then components can be assembled, but the manufacturing process is complex and shape matching is poor
Solution Approach 1:
The battery pack is divided into distinct functional modules: the battery cell, protection circuit module (PCB), and a unified frame structure. The frame is segmented into outer frame and inner frame portions, allowing independent assembly and positioning of components while maintaining overall structural integrity and simplifying the manufacturing process.
Solution Approach 2:
The outer frame and inner frame are integrated into a unified frame structure that combines both structural support and component positioning functions. This merging eliminates the need for separate positioning mechanisms and complex assembly steps, directly addressing the contradiction between manufacturing simplicity and assembly complexity.
2Manufacturing precision
If components are tightly assembled, then shape matching improves, but assembly difficulty increases
Solution Approach 1:
The frame structure incorporates pre-formed positioning protrusions and grooves that are manufactured in advance. These pre-positioned features guide component alignment during assembly, achieving high shape matching precision without requiring complex adjustment procedures or tight tolerance machining, thus resolving the contradiction between precision and assembly ease.
Solution Approach 2:
The inner frame acts as an intermediary component between the battery cell and PCB, providing a standardized interface with positioning features. This intermediary structure mediates the connection between components, ensuring precise shape matching while simplifying the assembly operation through standardized mating features.
3Manufacturing precision
If an inner frame is added between battery cell and PCB, then component positioning improves, but device complexity increases
Solution Approach 1:
The inner frame is designed to perform multiple functions simultaneously: structural support, component positioning, and electrical insulation. By consolidating these functions into a single component, the design achieves improved component positioning precision without proportionally increasing device complexity, as the same structural element provides multiple benefits.
Solution Approach 2:
The frame structure uses uniform material properties and consistent geometric features throughout, including the positioning protrusions and grooves. This homogeneity simplifies manufacturing and assembly processes while maintaining precise component positioning, reducing the overall complexity despite the addition of the inner frame.
Data Source
AI summary
A battery pack including a bare cell, the bare cell having a pair of first side portions opposite to each other, a pair of second side portions opposite to each other, and a pair of plane portions opposite to each other, the second side portions and the plane portions being connected to ends of the first side portions; a protection circuit module electrically connected to the bare cell; an inner frame between the bare cell and the protection circuit module, the inner frame accommodating the bare cell and exposing one side portion of the pair of first side portions; and an outer frame, the outer frame accommodating the bare cell, the protection circuit module, and the inner frame and exposing the pair of plane portions.