Battery Pack Protective Circuit Module Offset and Cover Integration

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Solution Overview

Problem

Existing battery packs face challenges in efficiently integrating protective circuit modules with bare cells, leading to potential short circuits and reduced spatial utility due to protruding weld beads and uneven surfaces during welding.

Innovation Solution

The battery pack design includes a bead protrusion prevention part on the cap plate, a protective circuit module offset from the terminal, and a first cover that accommodates the module with an exposure opening, ensuring the module is securely positioned and preventing weld beads from protruding, thus maintaining contact between lead plates and cap plates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the protective circuit module is positioned close to the terminal of the bare cell for compact design, then spatial utility is improved, but the risk of short circuits increases due to potential contact with protruding weld beads

Engineering Contradiction:

Improvespace required for protective circuit moduleVSAvoidrisk of short circuit

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The protective circuit module is extracted from the immediate vicinity of the terminal and positioned at an offset location on the cap plate, separating it from the welding area to eliminate short circuit risk while maintaining compact overall design

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The cap plate serves as an intermediary structure that provides a designated positioning area for the protective circuit module, physically separating it from the terminal and weld beads while maintaining electrical connectivity through the lead plate

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If welding is performed to connect the cap plate to the can, then electrical connectivity is improved, but weld beads protrude creating uneven surfaces that reduce manufacturing precision

Engineering Contradiction:

Improveelectrical connectivityVSAvoidsurface flatness

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The welding process is maintained for essential electrical connectivity, but the resulting weld beads are converted from harmful protrusions into beneficial positioning features by providing recessed areas on the cap plate where the protective circuit module can be accurately positioned and secured

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If the protective circuit module is offset from the terminal to prevent short circuits, then reliability is improved, but the space required for the module increases

Engineering Contradiction:

Improveshort circuit preventionVSAvoidspace for protective circuit module

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The cap plate performs multiple functions: it provides electrical connectivity, serves as a mounting surface for the protective circuit module, and creates positioning recesses through weld beads, thereby accommodating the module in an offset position without significantly increasing overall battery pack volume

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10707540B2Battery pack

Publication Date: 2020.07.07 SAMSUNG SDI CO LTD

AI summary

A battery packing includes: a bare cell; a protective circuit module electrically connected to the bare cell; a first lead plate connecting the protective circuit module and a terminal of the bare cell; and a first cover at an upper portion of the bare cell, wherein a portion of the first cover protrudes outward and accommodates the protective circuit module.