Battery Pack Frame Mounting Ledge Guide Member Circuit Fixation
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Solution Overview
Problem
Conventional secondary battery packs are prone to disconnection of secondary batteries and protective circuit modules due to external impacts, as they are not securely fixed within the pack case, leading to potential malfunction during sudden movements.
Innovation Solution
A battery pack design featuring a frame with a protruding mounting ledge and guide member, along with a reinforcement member formed through injection molding, which includes a fixing part with a fixing hole and guide groove to securely attach the circuit section to the frame, ensuring stable connections and preventing disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the pack case is sized slightly larger than the products to allow easy installation, then the ease of manufacture and installation is improved, but the stability and reliability of battery connection deteriorates due to loose fitting and jarred connections under external force
Solution Approach 1:
The pack case is divided into multiple functional components: a receiving space for batteries, a mounting ledge with fixing protrusions for securing batteries, and a separate protective circuit module housing. This segmentation allows each component to be optimized independently - the receiving space provides easy installation while the mounting ledge ensures reliable connection through dedicated fixing structures.
Solution Approach 2:
The mounting ledge acts as an intermediary structure between the pack case and the battery. It includes fixing protrusions that extend into receiving spaces on the battery, creating a mechanical interface that simultaneously enables easy installation (by guiding battery placement) and ensures reliable connection (through positive mechanical engagement that prevents jarred connections).
2Ease of manufacture
If molding resin is used to fill gaps and fix battery components together, then the ease of manufacture is improved, but the reliability deteriorates as components may still become disconnected under external impact
Solution Approach 1:
The mounting ledge with fixing protrusions provides beforehand mechanical support and positioning for the battery. This pre-established structural framework prevents the battery from moving or becoming disconnected under external impact, eliminating the need for molding resin while ensuring reliable connection from the outset.
Solution Approach 2:
The invention replaces the chemical bonding mechanism (molding resin) with a mechanical fastening system (mounting ledge with fixing protrusions). This mechanical system provides superior reliability under impact while maintaining ease of manufacture, as the fixed structure can be assembled through simple insertion and engagement without requiring resin application and curing processes.
3Reliability
If the secondary battery is securely fixed with a frame and mounting ledge, then the reliability of connection is improved, but the device complexity increases due to additional structural components
Solution Approach 1:
The mounting ledge serves multiple functions simultaneously: it provides mechanical support for the battery, guides battery insertion during assembly, secures the battery through fixing protrusions, and protects the battery from impact. This multi-functionality reduces the need for separate components, thereby maintaining simplicity while ensuring reliable fixation.
Solution Approach 2:
The mounting ledge and fixing protrusions are integrated as a single structural feature of the pack case, combining the functions of support, positioning, and securing. This merging of functions into one component achieves reliable battery fixation without increasing device complexity through multiple separate parts.
Data Source
AI summary
A battery pack including a secondary battery and a frame for mounting the secondary battery therein. A mounting ledge protrudes from one portion of the frame and a guide member protrudes from another portion of the frame. A circuit section is installed at a portion of the frame and inserted between the mounting ledge and the guide member so as to be connected to the secondary battery. A fixing part is provided in the frame and the circuit section in order to fix the circuit section to the frame.