Battery Pack PCB Housing Locking Mechanism for Vibration Isolation
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Solution Overview
Problem
Existing battery packs face challenges in mitigating damage from ultrasonic waves and vibrations during the bonding of cell leads and bus bars, which can lead to increased failure rates and damage to components like fuses and sensors mounted on the PCB.
Innovation Solution
The battery pack design incorporates a 2-stage locking mechanism for the PCB housing, allowing the PCB to be locked in positions that either prevent or allow elastic deformation of terminal clips, thereby minimizing the transfer of ultrasonic waves and vibrations to sensitive components, and includes a protrusion and engaging projections to facilitate easy detachment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the PCB housing is rigidly fixed to the connection board during bonding, then the bonding strength is improved, but ultrasonic waves and vibrations damage the PCB components
Solution Approach 1:
The locking part is divided into multiple engagement positions (first engagement position and second engagement position) that can be selectively activated. During bonding, the first engagement position is used to rigidly fix the PCB housing, providing strong bonding strength. After bonding, the second engagement position is used to isolate the PCB housing from vibrations, protecting components. This segmentation of the locking function resolves the contradiction between needing rigid fixation for bonding strength and needing vibration isolation for component protection.
2Reliability
If the terminal clip is isolated from vibrations, then component reliability is improved, but electrical connection stability deteriorates
Solution Approach 1:
The locking part is designed to dynamically change its engagement position based on the operational phase. In the first engagement position, it provides rigid fixation for stable electrical connection during bonding. In the second engagement position, it provides vibration isolation for component reliability during operation. The ability to switch between these states dynamically resolves the contradiction between connection stability and component reliability.
3Reliability
If the PCB module is permanently fixed, then assembly reliability is improved, but maintenance and replacement difficulty increases
Solution Approach 1:
The locking mechanism is segmented into multiple engagement positions, with the second engagement position providing a detached state that facilitates easy removal and installation of the PCB housing. This segmentation allows the system to maintain reliable assembly during operation while enabling easy maintenance when needed, resolving the contradiction between assembly reliability and ease of repair.
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 effectively reduces the risk of damage to components from ultrasonic waves and vibrations, enhances the reliability of the battery pack by protecting sensitive parts, and allows for convenient assembly and maintenance without detaching the PCB module.
Implementation Method 1
a terminal clip mounted on the PCB, the terminal clip configured to be selectively connected to and disconnected from the terminal pin of the bus bar
Implementation Method 2
a locking part configured to: in a first locking state, lock the PCB housing to the connection board at a first position in which the terminal pin of the bus bar mounted on the connection board does not elastically deform the terminal clip of the PCB; and in a second locking state, lock the PCB housing to the connection board at a second position in which the terminal pin elastically deforms the terminal clip
Data Source
AI summary
A battery pack may include a battery cell with a cell lead; a bus bar bonded to the cell lead and having a terminal pin; a connection board having the bus bar mounted thereon; and a printed circuit board (PCB). The PCB may have a terminal clip selectively connected to and disconnected from the terminal pin of the bus bar. The battery pack may also include a PCB housing defining a PCB accommodation space accommodating the PCB. The battery pack may further include a locking part that, in a first locking state, locks the PCB housing to the connection board at a first position where the terminal pin of the bus bar does not elastically deform the terminal clip of the PCB; and in a second locking state, lock the PCB housing to the connection board at a second position where the terminal pin elastically deforms the terminal clip.