Secondary Battery Pack Insulative Case Design
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Solution Overview
Problem
The existing secondary battery pack assembly process is complex and costly due to the need for multiple insulative tapes, which also compromises mechanical strength and dimensional stability, and exposes electrode terminals, leading to potential damage from external impacts and wrinkles on the battery pack's surface.
Innovation Solution
A secondary battery pack design that encases the protection circuit board within an electrically insulative case, reducing the number of parts required and using a fastening structure for the case and lid to secure the board, thereby protecting the circuit board from external impacts and preventing terminal exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulative tapes are used to connect the protection circuit board to the battery cell, then electrical insulation is achieved, but the assembly process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent combines multiple insulative tapes and their functions into a single integrated insulative case structure. The case is designed with built-in insulative properties that simultaneously provide electrical insulation and structural support, eliminating the need for separate insulative tapes and simplifying the assembly process.
Solution Approach 2:
The insulative case serves multiple functions: it provides electrical insulation between the protection circuit board and battery cell, offers mechanical protection against external impacts, maintains dimensional stability, and prevents electrode terminal exposure. This multi-functional design replaces multiple specialized components with a single versatile structure.
2Reliability
If multiple insulative tapes are used to secure the protection circuit board, then electrical insulation is provided, but mechanical strength and dimensional stability are reduced
Solution Approach 1:
The insulative case merges the functions of multiple insulative tapes into a single structurally robust component. The case is designed with sufficient thickness and rigidity to provide both electrical insulation and mechanical strength, eliminating the weakness associated with using multiple thin tapes that compromise structural integrity.
3Reliability
If insulative tapes are used to connect the protection circuit board, then electrical insulation is achieved, but the battery pack is vulnerable to external impact damage
Solution Approach 1:
The insulative case is designed as a multi-functional protective structure that simultaneously provides electrical insulation and mechanical protection. Its robust construction acts as a shield against external impacts, protecting both the protection circuit board and battery cell from damage while maintaining electrical insulation properties.
4Reliability
If multiple insulative tapes and parts are used, then safe connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent consolidates multiple separate insulative components into a single integrated insulative case, reducing the total number of parts that need to be procured, managed, and assembled. This consolidation directly reduces manufacturing costs while maintaining the safety and reliability of the connection.
Solution Approach 2:
The insulative case performs multiple functions that previously required separate components, including electrical insulation, mechanical protection, structural support, and prevention of terminal exposure. This multi-functionality reduces the total component count and associated manufacturing costs.
5Reliability
If insulative tapes are used to secure the protection circuit board, then electrical insulation is provided, but wrinkles form on the battery pack surface
Solution Approach 1:
The insulative case provides a smooth, continuous outer surface that eliminates wrinkles by replacing the uneven appearance of multiple taped layers. The case is designed with a sleek finish that maintains the aesthetic quality of the battery pack while providing all necessary insulative functions.
Data Source
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AI summary
Disclosed herein is a secondary battery pack including a battery cell having an anode terminal and a cathode terminal formed at one face having a sealed surplus portion and a protection circuit module (PCM) electrically connected to the battery cell via the anode terminal and the cathode terminal, wherein the PCM includes a board having a protection circuit formed thereon, the board being provided with an anode terminal connection part and a cathode terminal connection part connected to the anode terminal and the cathode terminal, respectively, a PCM case configured to receive the board through an open face thereof so that the PCM case surrounds the board, and an electrically insulative lid to close the open face of the PCM case. The board is coupled to the anode terminal and the cathode terminal of the battery cell via the anode terminal connection part and the cathode terminal connection part, the board is disposed in the PCM case in a state in which the board is parallel to the battery cell, the open face of the PCM case is closed by the electrically insulative lid, and the PCM case is mounted to the sealed surplus portion of the battery cell.