Battery Pack Holder Frame Inversion for Gap Elimination
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Solution Overview
Problem
Conventional polymer battery packs require additional parts and manufacturing processes due to gaps between the bare cell and protection circuit member, increasing complexity and costs.
Innovation Solution
The bare cell is coupled to the inner side of a holder frame, and the protection circuit member is coupled to the outer side, eliminating the need for hot-melt resin or additional holders and simplifying the frame mold, thereby reducing parts and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot-melt resin or injection-molded holder is used to reduce gap between bare cell and protection circuit member, then gap reduction is achieved, but number of parts increases and manufacturing complexity increases
Solution Approach 1:
The invention extracts and eliminates the unnecessary hot-melt resin or injection-molded holder from the battery pack structure. By repositioning the protection circuit member to be installed on the outer side of the frame rather than inside, the gap-filling components are completely removed, reducing part count while maintaining proper spacing between the bare cell and protection circuit member
Solution Approach 2:
The invention inverts the conventional installation approach by placing the protection circuit member on the outer side of the frame instead of inside. This inversion eliminates the need for gap-reducing measures like hot-melt resin or additional holders, as the member is naturally positioned away from the bare cell by the frame structure itself
2Stability of the object's composition
If protection circuit member is installed inside the frame, then structural integration is improved, but hole formation is required in frame mold decreasing productivity and increasing manufacturing costs
Solution Approach 1:
The invention extracts the protection circuit member from the interior installation position and relocates it to the outer side of the frame. This eliminates the requirement for holes in the frame mold, allowing the frame to be manufactured as a simple, hole-free structure that enhances mold productivity and reduces manufacturing costs while maintaining structural integration through the coupling mechanism
3Ease of manufacture
If complex frame mold with holes is used to install protection circuit member inside, then protection circuit member installation is achieved, but manufacturing costs increase
Solution Approach 1:
The invention inverts the installation location from inside to outside of the frame, which eliminates the need for complex hole-formed molds. The frame mold becomes simple and straightforward to manufacture, while the protection circuit member is still properly installed and secured on the outer side through the coupling structure
Solution Approach 2:
The invention removes the requirement for complex hole-formed molds by extracting the protection circuit member from the interior installation position. The frame is designed as a simple structure without holes, significantly simplifying the molding process and reducing manufacturing costs
Data Source
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AI summary
Disclosed are a polymer battery pack and a method for manufacturing the same. In the polymer battery pack, a bare cell and a protection circuit member are separated from each other by a holder frame such that the bare cell is coupled to the inner side of the holder frame and the protection circuit member is coupled to the outer side of the holder frame. The method for manufacturing the polymer battery pack includes: coupling a bare cell to the inner side of a holder frame; electrically connecting the bare cell to a protection circuit member; coupling the protection circuit module to the holder frame; coupling a cover to the holder frame; attaching an external label to the cover; attaching a water sensitive paper to the cover; and performing a function test for the battery.