Secondary Battery Pack Insulative Mounting Member Coupling

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Solution Overview

Problem

Existing secondary battery pack manufacturing processes face challenges such as complex assembly, low safety due to welding or soldering requirements, and exposure of coupling members leading to potential short circuits, which complicate the manufacturing process and affect the aesthetic appeal.

Innovation Solution

A secondary battery pack design featuring an insulative mounting member coupled to the battery cell through a specific coupling structure using coupling grooves and through-holes, with coupling members like metal pins or screws inserted to ensure secure and non-exposed connections, reducing the number of top-mounted members and simplifying assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding or soldering is used to connect the protection circuit module to the battery cell, then the coupling force between the PCM and battery cell is improved, but the manufacturing complexity increases and skilled workers are required

Engineering Contradiction:

Improvecoupling forceVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the welding/soldering process with a mechanical pressing coupling structure. The PCM is coupled to the battery cell through a pressing force applied to the coupling member, eliminating the need for welding equipment and skilled workers while maintaining sufficient coupling strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a coupling member as an intermediary component between the PCM and the battery cell. This coupling member facilitates the mechanical connection, allowing the PCM to be securely attached through pressing without direct welding to the battery terminals.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If welding or soldering is used to connect the protection circuit module to the battery cell, then the coupling force between the PCM and battery cell is improved, but the safety of the battery cell deteriorates

Engineering Contradiction:

Improvecoupling forceVSAvoidbattery cell safety

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces thermal welding/soldering processes with a mechanical pressing system. This substitution eliminates the risk of thermal damage to the battery cell, internal short circuits, and other safety issues associated with welding, while still achieving reliable coupling through mechanical force.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If coupling members are exposed to the outside of the insulative cap, then the coupling structure is simplified, but the aesthetic appearance deteriorates and short circuit risk increases

Engineering Contradiction:

Improvecoupling structure complexityVSAvoidaesthetic appearance

Core Design Contradiction:

Device complexityVSShape

Solution Approach 1:

The patent employs a nested structure where the coupling member is positioned inside the insulative cap rather than being exposed externally. The insulative cap covers and protects the coupling member, creating a compact integrated assembly that maintains aesthetic appearance while preserving the coupling function.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The insulative cap serves as an intermediary component that both protects the coupling member and provides aesthetic coverage. It eliminates the visual exposure of metal coupling members while maintaining the mechanical coupling function through its structural design.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Device complexity

If coupling members are exposed to the outside of the insulative cap, then the coupling structure is simplified, but the risk of electrical short circuit increases

Engineering Contradiction:

Improvecoupling structure complexityVSAvoidshort circuit risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The insulative cap acts as an intermediary protective barrier between the exposed coupling members and the external environment. Its insulative material properties prevent electrical short circuits by isolating the conductive coupling members from contact with other conductive elements or moisture.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coupling member is nested within the insulative cap structure, which provides continuous electrical insulation. This nested arrangement ensures that the conductive coupling member never comes into direct contact with external conductive surfaces, eliminating short circuit risks.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS8137837B2Secondary battery pack having excellent production process property and structural stability

Publication Date: 2012.03.20 LG ENERGY SOLUTION LTD

AI summary

A secondary battery pack is provided. The secondary battery pack includes a battery cell having an electrode assembly of a cathode/separator/anode structure mounted in a battery case together with an electrolyte in a sealed state, an insulative mounting member having openings, through which electrode terminals of the battery cell are exposed to the outside, the insulative mounting member being constructed in a structure in which a safety element is mounted to the top of the insulative mounting member, the insulative mounting member being in direct contact with the top of the battery cell, and an insulative cap coupled to the top of the battery cell such that the insulative cap surrounds the insulative mounting member while the safety element is mounted to the insulative mounting member.