Battery Pack Insulating Member Design for Spring Back Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery pack designs face issues with lead time in the insulating tape attaching process and contact failure between battery cells and connecting plates due to the spring back of the bent insulating tape.
Innovation Solution
A battery pack design featuring a first and second connecting plate with an insulating member that includes a first region between battery cells and second regions on their outer surfaces, which are bent along specific lines with recesses or notches, and an adhesive layer to prevent spring back and ensure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bent insulating tape is used to attach the connecting plate to battery cells, then the insulating plate can be secured in place, but the bent insulating tape causes spring back that raises the connecting plate and disrupts electrical contact
Solution Approach 1:
The insulating tape is divided into multiple segments: a body portion and multiple bent portions. Each bent portion is separately formed with bending lines and recesses to control the shape. This segmentation allows each portion to independently maintain its bent shape without causing spring back to the connecting plate, resolving the contradiction between securing the plate and maintaining stable contact.
Solution Approach 2:
The bent portions are pre-formed with bending lines and recesses before attachment to the connecting plate. This preliminary shaping ensures that when the tape is attached, the bent portions maintain their predetermined shape and prevent spring back, thereby ensuring stable electrical contact from the outset.
2Object-affected harmful factors
If insulating tape is attached before welding the connecting plate to battery cells, then insulation is provided during welding, but the process lead time increases due to the additional attaching step
Solution Approach 1:
The insulating tape is designed to be attached together with the connecting plate to the battery cells in a single welding operation. The tape's body portion and bent portions are integrated into one attachment process, eliminating the need for a separate insulating tape attachment step and thereby reducing process lead time while maintaining insulation protection during welding.
3Ease of operation
If the insulating tape is bent to provide space for wire welding, then wire attachment is enabled, but the bent tape raises the connecting plate and causes contact failure
Solution Approach 1:
The insulating tape has different structural characteristics in different regions: the body portion provides insulation, while the bent portions with bending lines and recesses provide localized wire attachment spaces. The recesses in the bent portions create gaps that allow wires to be welded without interfering with the connecting plate's contact with battery cells, thus enabling wire welding while maintaining contact reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces the lead time for the insulating tape attaching process, prevents contact failure between battery cells and connecting plates, and allows for easy re-attachment of the insulating member, enhancing the reliability and efficiency of the electrical connection.
Implementation Method 1
The insulating member may include an adhesive layer on a surface thereof
Data Source
AI summary
Disclosed is a battery pack that makes it possible to decrease a lead time of an insulating tape attaching process, and re-attach an insulating member. The battery pack includes a plurality of battery cells, a protection circuit module that controls charging and discharging of the battery cells, a first connecting plate electrically connecting the battery cells to each other, a second connecting plate electrically connected to the first connecting plate, and bent from the first connecting plate; and an insulating member disposed between the battery cell and the first and second connecting plates. The insulating member includes a first region placed between neighboring ones of the battery cells, and a plurality of second regions that are bent from the first region and are placed on outer surfaces of the neighboring battery cells, respectively.