Battery Pack Molding and Adhesive Integration for Assembly Simplification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly process of rechargeable battery packs is complicated due to the increased number of parts, and faulty connections can occur if the holder and battery cell are not properly attached, leading to potential issues with overcharge, over-discharge, overcurrent, and short circuits.
Innovation Solution
A rechargeable battery pack design that reduces the number of parts by burying the protection element and management package within a molding portion, using connecting tabs with bending portions to create a height difference, and an adhesive member to attach the molding portion to the battery cell, simplifying assembly and absorbing impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a holder is used to attach the protection management package and PTC element to the battery cell, then the protection elements can be securely mounted, but the assembly process becomes complicated and the number of parts increases
Solution Approach 1:
The holder is integrated into the battery cell structure by forming a recess directly on the battery cell surface. The protection management package and PTC element are mounted within this recess, eliminating the need for a separate holder component while maintaining secure mounting through the adhesive member and structural integration.
2Ease of manufacture
If a holder is used to attach the protection management package and PTC element, then mounting is facilitated, but the number of parts increases
Solution Approach 1:
The holder function is merged with the battery cell by forming a recess directly on the battery cell surface. This integration reduces the total part count by eliminating the separate holder component while maintaining the mounting facilitation function through the recess structure and adhesive member.
3Productivity
If the holder and battery cell are not properly attached, then assembly may be faster, but connection between electrode terminal and connecting tab becomes faulty
Solution Approach 1:
The recess is pre-formed on the battery cell surface during battery cell manufacturing, before the protection elements are mounted. This preliminary preparation ensures proper positioning and attachment surfaces are already in place, enabling both fast assembly and reliable connection without requiring precise alignment during the assembly process.
Solution Approach 2:
An adhesive member is introduced as an intermediary between the protection elements and the battery cell recess. This adhesive mediator ensures reliable connection and proper attachment while allowing for efficient assembly, bridging the gap between the mounting surface and the protection elements.
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 simplifies the assembly process, reduces the number of parts, and effectively prevents overcharge, over-discharge, overcurrent, and short circuits by fully enclosing the protection element and management package, while also absorbing impacts through the molding portion's structure.
Implementation Method 1
an adhesive member disposed between the molding portion and the battery cell to attach them
Implementation Method 2
the first connecting tab has a bending portion that is bent between the electrode terminal and the protection element to set a height difference
Data Source
AI summary
A rechargeable battery pack is disclosed. In one aspect, the battery pack includes a battery cell including an electrode terminal in a cap plate and configured to perform charging and discharging operations, a protection element connected to the electrode terminal via a first connecting tab and a protection management package connected to a second connecting tab of the protection element and connected to the cap plate via an electrode tab. The battery pack also includes a molding portion enclosing the protection element and the protection management package; and an adhesive member disposed between the molding portion and the battery cell to attach them, wherein the first connecting tab has a bending portion bent between the electrode terminal and the protection element so as to set a height difference.