Battery Pack PCM Layout With Integrated Insulation and Fewer Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs face inefficiencies in manufacturing due to the need for additional parts to prevent anode connection between the Protection Circuit Module (PCM) and the battery cell, leading to decreased process efficiency, increased costs, and reduced energy density.
Innovation Solution
A battery pack design featuring a battery cell with electrode leads and a Protection Circuit Module (PCM) surrounded by a thermally contracting tube, which includes connection terminals exposed outside to prevent anode connection, allowing for reduced parts and increased energy density by utilizing the dead space for the PCM.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tape or injection-molded case is applied to prevent anode connection between PCM and battery cell, then insulation is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the insulation function with the battery cell case structure itself. The case includes an isolation protrusion that directly prevents anode contact between the PCM and battery cell, eliminating the need for separate tape or injection-molded case components. This merging of functions reduces part count while maintaining insulation reliability.
2Reliability
If a tape or injection-molded case is applied to prevent anode connection, then insulation is improved, but manufacturing efficiency decreases
Solution Approach 1:
The isolation protrusion is integrated into the battery cell case as a single molded structure, combining the case formation and insulation provision into one manufacturing step. This eliminates separate assembly operations for applying tapes or installing injection-molded cases, thereby improving manufacturing efficiency and productivity.
3Reliability
If a tape or injection-molded case is applied to prevent anode connection, then insulation is improved, but energy density decreases
Solution Approach 1:
The insulation function is integrated into the existing battery cell case structure through the isolation protrusion, eliminating the need for additional insulation materials. This reduces the volume occupied by non-active materials and increases the space available for battery cells, thereby improving energy density while maintaining insulation effectiveness.
4Quantity of substance
If PCM size is reduced to achieve target energy density, then energy density is improved, but reliability deteriorates due to insufficient distance between circuit patterns
Solution Approach 1:
The patent uses the isolation protrusion to create vertical separation between the PCM and battery cell, utilizing the third dimension (height/depth) rather than relying solely on horizontal spacing. This allows the PCM to be positioned closer to the battery cell in the planar dimensions while maintaining adequate insulation through the protrusion's vertical barrier, thus enabling smaller PCM dimensions without compromising reliability.
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 enhances process efficiency, productivity, and energy density by minimizing the number of parts required to prevent anode connection, thereby improving product reliability and quality.
Implementation Method 1
a thermally contracting tube configured to surround the PCB
Data Source
AI summary
Discussed is a battery pack, which may include a battery cell having a pair of electrode leads, and a Protection Circuit Module (PCM) including a Printed Circuit Board (PCB) having a pair of connection terminals respectively coupled to the pair of electrode leads and a thermally contracting tube configured to surround the PCB, the PCM being configured to prevent overcharging of the battery cell.