Battery Pack Label Layout for Thin Edge Insulation
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Solution Overview
Problem
Conventional battery packs with labels attached face challenges in reducing thickness while preventing short circuits, as the label's overlapping edges can lead to increased thickness and potential short circuits when trying to remove it for larger capacity or thinner designs.
Innovation Solution
A battery pack design featuring a label that wraps the battery cell without overlapping portions on the rear surface, using a protection circuit module (PCM) and adhesion parts to ensure a single-layer attachment, reducing thickness and preventing short circuits by using insulating materials and strategically placed adhesion parts to maintain edge insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the label is attached with overlapping edges to cover the whole battery pack, then the insulating properties are improved and short circuit is prevented, but the thickness of the battery pack increases
Solution Approach 1:
The label is divided into multiple separate adhesive portions (first adhesive portion, second adhesive portion, third adhesive portion, fourth adhesive portion) that are attached to different surfaces of the battery pack. Each portion is a separate segment that does not overlap with others, eliminating the need for overlapping edges while maintaining continuous insulation coverage.
Solution Approach 2:
The label extends into the thickness direction of the battery pack, with adhesive portions attached to front, rear, side, top, and bottom surfaces. This multi-dimensional attachment strategy allows the label to provide comprehensive insulation without requiring overlapping edges in the same plane, thus reducing thickness.
2Length of stationary object
If the label is removed to reduce thickness, then the battery pack thickness is reduced, but the edges become exposed and short circuit may occur
Solution Approach 1:
The insulation function is segmented across multiple label portions attached to different surfaces. The first adhesive portion covers the front surface, the second covers the rear surface, the third covers the side surface, and the fourth covers the top or bottom surface. This segmentation allows each portion to be thin without overlapping while collectively providing complete edge coverage and insulation.
Solution Approach 2:
The label serves multiple functions simultaneously: it provides insulation, prevents short circuits, and maintains a thin profile. By attaching the label to multiple surfaces rather than using overlapping edges, the label achieves comprehensive protection without the thickness penalty of traditional overlapping configurations.
3Reliability
If the label is made to cover the whole battery pack, then the insulating coverage is improved, but the device complexity increases due to overlapping portions
Solution Approach 1:
The label is segmented into four distinct adhesive portions attached to different surfaces of the battery pack. This segmentation simplifies the overall structure by eliminating overlapping portions, making the label easier to manufacture, attach, and inspect while maintaining complete insulating coverage across all surfaces.
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
The solution effectively reduces the battery pack's thickness and prevents short circuits by ensuring non-overlapping label attachment, enhancing safety and capacity without increasing thickness, while maintaining insulating properties and preventing static electricity introduction.
Implementation Method 1
a label wrapping the battery cell, to which the PCM is coupled, so that a portion of the label attached to a rear surface of the battery cell in a thickness direction is attached as a single layer with having no overlapping portion
Implementation Method 2
The battery pack may have a reduced thickness when compared with that of the existing battery pack and prevent short circuit from occurring at the edge
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
The present invention relates to a battery pack, and more particularly, to a battery pack in which a label wrapping a battery cell coupled to a PCM has a thin shape, which does not have an overlapping portion.