Battery Pack Protection Module Layout for Insulated Cell Connection
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Solution Overview
Problem
Existing battery pack designs face challenges in efficiently integrating protection modules with battery cells, particularly in ensuring reliable electrical connections and adequate insulation to prevent electrical interference and physical damage.
Innovation Solution
The proposed battery pack design incorporates a protection module package with an insulating frame, a circuit portion, and an insulating block. The insulating frame includes a base portion on the battery cell's terrace portion and a first partition wall facing the battery cell, providing insulation and structural support for the circuit portion. The circuit portion includes a circuit board with a connection tab connected to the battery cell's electrode and a safety element, which is insulated by the insulating block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protection module package is integrated with a battery cell, then electrical connection reliability is improved, but device complexity increases
Solution Approach 1:
The protection module package is merged with the battery cell to form an integrated assembly. The insulating frame is directly positioned on the terrace portion of the battery cell, combining the protection module with the battery cell structure to improve electrical connection reliability while reducing overall device complexity through integration.
Solution Approach 2:
The insulating frame serves multiple functions simultaneously: it provides electrical insulation between the battery cell and protection module, offers structural support for the protection module package, and facilitates mechanical attachment. This multi-functionality reduces the need for separate components, thereby improving reliability without proportionally increasing complexity.
2Object-affected harmful factors
If an insulating frame and insulating block are added to provide insulation, then protection against electrical interference is improved, but manufacturing complexity increases
Solution Approach 1:
The insulation system is segmented into two distinct components: an insulating frame and an insulating block. The frame is positioned on the terrace portion and provides peripheral insulation, while the block is inserted into the frame to provide additional insulation for the circuit portion. This segmentation allows each component to be manufactured separately using standard processes, then assembled together, reducing overall manufacturing complexity while maintaining effective insulation.
Solution Approach 2:
The insulating frame acts as an intermediary structure that facilitates the assembly of the insulating block and provides a mounting platform for the protection module. This intermediary component simplifies the manufacturing process by creating a modular assembly sequence where components can be manufactured independently and then easily combined.
3Volume of moving object
If the protection module package is compactly configured, then space utilization is improved, but insulation effectiveness may be compromised
Solution Approach 1:
The insulating block is nested within the insulating frame, with the block positioned inside the hollow space of the frame. This nested configuration maximizes space utilization by having one insulating component contain another, creating a compact protection module package while maintaining effective insulation through the combined thickness of both insulating elements.
Solution Approach 2:
The insulation is provided in multiple dimensions: the frame provides insulation in the radial direction around the battery cell, while the block provides insulation in the axial direction within the frame. This multi-dimensional insulation approach ensures effective electrical isolation in all directions despite the compact overall volume of the protection module package.
Data Source
AI summary
A battery pack and a method of manufacturing the battery pack including a battery cell including a terrace portion from which an electrode is drawn out; and a protection module package electrically connected to the battery cell, wherein the protection module package includes an insulating frame including a base portion on the terrace portion of the battery cell, and a first partition wall on the base portion and facing the battery cell, a circuit portion on the insulating frame, and an insulating block covering at least a portion of the circuit portion.