Low-Height Battery Pack Lead Insulation for Short-Circuit Prevention
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Solution Overview
Problem
Existing battery packs for devices like electric vehicles and hybrid vehicles face challenges in power and capacity management, requiring multiple batteries connected in modules, which can lead to increased output voltages or currents, and there is a need for a compact and safe electrical connection structure to prevent short circuits.
Innovation Solution
A battery pack design featuring a battery cell with a height less than its electrode diameter, using compressible conductors for electrical connection, an insulating adhesive layer, and an insulating cover layer with openings to expose leads, forming a simple charge-discharge path and preventing short circuits through unintended external conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple batteries are connected in modules to handle power and capacity requirements, then power and capacity are improved, but device height and complexity increase
Solution Approach 1:
The patent transitions from vertical stacking of multiple battery cells (height direction) to horizontal arrangement of battery modules (lateral direction). The housing contains multiple battery modules arranged side-by-side, with each module containing batteries in a compact configuration. This dimensional change allows high power and capacity without increasing device height.
2Power
If multiple batteries are connected in modules to handle power and capacity requirements, then power and capacity are improved, but device complexity increases
Solution Approach 1:
The housing serves multiple functions simultaneously: it contains the battery modules, provides structural support, enables lateral heat dissipation through heat radiating protrusions, and facilitates modular assembly. This multi-functionality reduces the need for separate components, thereby reducing overall device complexity while maintaining high power capability.
3Reliability
If compressible conductors are used for electrical connection, then electrical connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The compressible conductor automatically adjusts its compression force based on the contact surface conditions. When assembled, the conductor's elastic properties enable it to self-adjust and maintain reliable electrical connection without requiring precise pre-setting of compression force or complex adjustment mechanisms, thereby improving reliability while simplifying manufacturing.
4Device complexity
If leads are exposed through insulating cover layer, then electrical connection is simplified, but short circuit risk increases
Solution Approach 1:
The insulating cover layer is designed with selective openings only at positions where electrical connection is required. The openings are precisely positioned and sized to expose only the necessary portions of leads for connection, while the surrounding areas maintain full insulation. This localized insulation approach simplifies electrical connection while minimizing short circuit risk.
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 design results in a compact, safe battery pack with improved safety by preventing short circuits and enabling effective use in slim devices with a low height, suitable for devices requiring high power and capacity.
Implementation Method 1
compressible conductors having a large height reduction when compressed for electrical connection with the battery cell
Implementation Method 2
compressible conductors having a large height reduction when compressed for electrical connection with the battery cell
Implementation Method 3
an insulating adhesive layer between the first surface and the first lead
Implementation Method 4
an insulating cover layer on the first and second leads, the insulating cover layer including an opening through which portions of the first and second leads are exposed
Data Source
AI summary
A battery pack includes: a battery cell including a first surface, a first electrode on the first surface, a second electrode on the first surface, a second surface opposing the first surface, and a lateral surface connecting the first surface and the second surface to each other; first and second leads above the first and second electrodes, the first and second leads being respectively connected to the first and second electrodes; an insulating adhesive layer between the first surface and the first lead; and an insulating cover layer on the first and second leads, the insulating cover layer including an opening through which portions of the first and second leads are exposed.