Battery Pack Insulation Member for Polarity Pin Isolation
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Solution Overview
Problem
Existing battery pack designs require insulation of the entire protection circuit module, leading to additional process work, material costs, and potential issues with uniform appearance and separation due to the flexibility of insulation tapes, while direct welding of flanges can damage the electrode assembly.
Innovation Solution
An insulation member that covers only the polarity pin exposed to the case without covering the protection circuit module, featuring coupling protrusions and guide grooves for secure attachment, and a method involving molding to form the insulation member and flange integration through protruding portions to avoid direct welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation tape is used to cover the protection circuit module, then electrical insulation is achieved, but additional process work and material costs increase
Solution Approach 1:
The insulation member combines multiple functions into a single integrated component: it provides electrical insulation for the polarity pin, structural support through coupling protrusions, and positioning guidance via guide grooves. This merging eliminates the need for separate insulation tapes and reduces assembly steps.
Solution Approach 2:
The insulation member serves multiple purposes simultaneously: it insulates the polarity pin from the case, provides mechanical coupling between components, guides the positioning of the protection circuit module, and prevents short circuits. This multi-functionality reduces the overall number of components needed.
2Reliability
If insulation tape is used to cover the protection circuit module, then electrical insulation is achieved, but material costs increase
Solution Approach 1:
The insulation member integrates insulation material with structural coupling elements into a single molded component, eliminating the need for separate insulation tapes and reducing total material consumption.
Solution Approach 2:
The insulation member is designed with optimized dimensions and material properties to provide sufficient electrical insulation only where needed (at the polarity pin location), rather than covering the entire protection circuit module, thereby reducing material usage.
3Strength
If flange is directly welded to the battery cell, then structural strength is achieved, but the electrode assembly is damaged
Solution Approach 1:
The insulation member acts as an intermediary component between the flange and the battery cell. It provides a mounting surface for the flange while preventing direct contact and potential damage to the electrode assembly, thus maintaining structural strength without causing harm.
Solution Approach 2:
The mounting structure is segmented into separate functional components: the insulation member provides electrical insulation and positioning, while the flange provides mechanical attachment. This segmentation allows the flange to be mounted without directly welding to the battery cell, avoiding damage to the electrode assembly.
Data Source
AI summary
An insulation member includes an insulating material shaped into a volumetric shape, and interior space inside the volumetric shape, wherein the volumetric shape does not cover a protection circuit module on a case of a battery pack, the volumetric shape covering a polarity pin electrically connected to the battery pack and exposed to an outside of the case.