Battery Pack Holder Protrusion Notch Design
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Solution Overview
Problem
The existing battery pack manufacturing process faces challenges in achieving a strong coupling force between the holder and the protection circuit board due to size mismatches between the coupling protrusion and groove, leading to increased manufacturing costs and inefficiencies.
Innovation Solution
The battery pack design incorporates a holder with a protrusion featuring a first and second supporting surface and a notch, allowing for flexible coupling with a corresponding groove on the protection circuit board, enabling improved assembly and maintaining a consistent coupling force even with minor deviations in size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fixed-size prismatic coupling protrusion is used, then the holder structure is simple, but the coupling force is insufficient due to size mismatch between protrusion and groove
Solution Approach 1:
The coupling protrusion is designed with a flexible structure that can elastically deform during assembly. The protrusion includes a first supporting surface, a second supporting surface, and a notch between them, allowing it to bend and adapt to size mismatches between the protrusion and groove, thereby maintaining strong coupling force despite dimensional variations.
Solution Approach 2:
The protrusion's geometric parameters are optimized to enable flexible coupling. By configuring specific surfaces (first supporting surface, second supporting surface) and a notch, the protrusion can change its effective engagement parameters during assembly, allowing it to accommodate size differences and maintain adequate coupling force.
2Manufacturing precision
If mold adjustment is performed to address size mismatch, then coupling precision is improved, but manufacturing cost and time increase
Solution Approach 1:
The flexible protrusion structure performs self-adjustment during assembly through elastic deformation. It automatically compensates for size mismatches between the protrusion and groove without requiring external mold adjustments or precision control, thereby maintaining high coupling precision while avoiding additional manufacturing steps.
Solution Approach 2:
The protrusion's geometric parameters are designed to enable automatic adaptation to dimensional variations. The flexible structure allows the protrusion to change its effective engagement dimensions during assembly, achieving precise coupling without requiring mold adjustments or specialized manufacturing processes.
3Strength
If a flexible protrusion with supporting surfaces and notch is used, then coupling force is enhanced, but the fastening part structure becomes more complex
Solution Approach 1:
The coupling protrusion incorporates a flexible structure with a notch that enables elastic deformation. This dynamic characteristic allows the protrusion to bend and adapt to size mismatches during assembly, maintaining strong coupling force while using a relatively simple structural configuration consisting of basic geometric elements (surfaces and notch).
Solution Approach 2:
The protrusion's geometric parameters (first supporting surface, second supporting surface, notch) are configured to achieve flexible coupling with minimal structural complexity. The design uses straightforward geometric features rather than complex mechanisms, allowing the structure to adapt to dimensional variations while remaining simple to manufacture and assemble.
Data Source
AI summary
Provided is a battery pack, which can increase coupling force between a holder and a protection circuit board, and improve processability and productivity. The battery pack includes a bare cell, a holder disposed at one side of the bare cell and having a first fastening part, and a protection circuit assembly disposed at one side of the holder and having a second fastening part coupled to the first fastening part, wherein one of the first and second fastening parts is a protrusion and the other is a groove, and the protrusion includes a first supporting surface, a second supporting surface and a notch formed between the first and second supporting surfaces. Also, the battery pack includes a bare cell, a holder disposed at one side of the bare cell and having a first fastening part, and a protection circuit assembly disposed at one side of the holder and having a second fastening part coupled to the first fastening part, wherein the first fastening part is a first protrusion and the second fastening part is a second protrusion, and one of the first and second protrusions includes a first supporting surface, a second supporting surface and a notch formed between the first and second supporting surfaces and the other is formed in the shape of a square pillar.