Battery Pack Insulation Holder Fixing Tab Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing battery pack designs face challenges in securely fixing the protection circuit module to the battery cell, particularly when the external terminal is close to the short side surfaces, leading to potential delamination or deviation due to external shocks, especially when the distance between the terminal and the short side surfaces is less than 6.5 mm.
Innovation Solution
A battery pack design that incorporates an insulation holder between the protection circuit module and the battery cell, using a conductive tab for electrical connection and a fixing tab attached to the protection circuit module, which is coupled to the insulation holder in a hook manner, allowing stable fixation without welding, even at close distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the external terminal is positioned close to the short side surfaces (less than 6.5 mm distance), then the battery pack size is reduced, but the protection circuit module cannot be properly fixed and may delaminate or deviate
Solution Approach 1:
An insulation holder is introduced as an intermediary component between the protection circuit module and the battery cell. The holder includes a fixing hole that receives a fixing tab, creating a mechanical interlocking structure that enables stable fixation even when the external terminal is positioned close to the short side surfaces, thus resolving the conflict between compact size and fixation reliability
2Reliability
If the external terminal is positioned at least 6.5 mm away from the short side surfaces, then the protection circuit module can be properly fixed, but the battery pack size increases
Solution Approach 1:
The insulation holder acts as a mediator that decouples the fixation requirement from the terminal positioning constraint. By providing a dedicated fixing structure (fixing hole and fixing tab) on the holder, the system achieves reliable fixation without requiring the external terminal to be positioned at a minimum distance from the short side surfaces, thereby reducing overall battery pack size
3Strength
If welding is used to fix the protection circuit module, then strong fixation is achieved, but the complexity of manufacturing increases
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a purely mechanical interlocking system consisting of the fixing tab inserted into the fixing hole of the insulation holder. This mechanical substitution eliminates the need for welding equipment and processes, reducing manufacturing complexity while maintaining strong fixation strength through the hook-shaped engagement structure
Data Source
AI summary
A battery pack includes a battery cell; an insulation holder coupled to the battery cell, the insulation holder having a fixing hole; and a protection circuit module coupled to the insulation holder, the protection circuit module having a fixing tab, wherein the fixing tab is fixed to the battery cell through the fixing hole.