Battery Pack Protection Circuit Module Case Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity and cost of manufacturing battery packs with embedded type secondary batteries are increased due to the need for multiple insulative tapes and components, which also compromise mechanical strength and assembly efficiency.
Innovation Solution
A battery pack design featuring a module case with open surfaces and a PCB receiving part allows for reduced components and simplified assembly, enhancing stability and electric capacity while eliminating the need for additional fixing members and insulative tapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulative tapes and components are used to ensure electrical isolation and safety, then safety and electrical isolation are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the insulative case, PCB mounting structure, and safety element housing into a single modular PCM unit. The insulative case simultaneously provides electrical isolation, structural support, and mounting functions that previously required separate components and multiple assembly steps.
Solution Approach 2:
The insulative case serves multiple functions: it provides electrical isolation between conductive parts, acts as a mechanical housing for the PCB and safety elements, provides structural support for mounting on the battery cell, and incorporates ribs that serve both as strengthening elements and alignment features.
2Reliability
If multiple insulative tapes and fixing members are used to secure the PCM, then reliability of connection is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The fixing ribs are integrated directly into the insulative case structure, eliminating the need for separate fixing members. The ribs protrude from the case and engage with corresponding features on the battery cell, providing secure mechanical attachment as part of the case itself.
Solution Approach 2:
The insulative case is made from a material that combines electrical insulation properties with sufficient mechanical strength to provide both electrical isolation and structural fixing functions, replacing the need for separate insulative tapes and mechanical fasteners.
3Reliability
If insulative tapes are used for electrical isolation, then electrical safety is improved, but mechanical strength and structural stability deteriorate
Solution Approach 1:
The insulative case is constructed from a material that exhibits both electrical insulation properties and high mechanical strength. This composite material approach replaces weak insulative tapes with a structurally robust insulative housing that provides both electrical isolation and mechanical support.
Solution Approach 2:
The insulative case features an asymmetric design with thickened regions and integrated ribs positioned strategically to provide enhanced mechanical strength at critical stress points while maintaining electrical isolation throughout the structure.
4Reliability
If PCM fixing members are used to secure the protection circuit module, then connection reliability is improved, but available space for battery capacity decreases
Solution Approach 1:
The mounting function is merged into the insulative case structure itself through integrated fixing ribs, eliminating the need for separate PCM fixing members. This integration allows the battery pack design to utilize space that would have been occupied by external fixing components.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Disclosed herein is a battery pack configured to have a structure including a plate-shaped battery cell having electrode terminals formed at one side thereof including a sealed surplus part and a protection circuit module (PCM) mounted at the sealed surplus part, wherein each of the electrode terminals of the battery cell is made of a plate-shaped conductive member, the PCM includes a protection circuit board (PCB), a safety element electrically connected between one of the electrode terminals formed at one side of the battery cell and the PCB or loaded on the PCB, an external input and output terminal electrically connected to a protection circuit of the PCB, and an electrically insulative module case in which the PCB and the safety element are mounted in a state in which the external input and output terminal extends outside, the module case is configured to have a structure in which two outer surfaces of the module case are open outward to form a first open surface and a second open surface, the module case is provided at an interior thereof with a PCB receiving part, and the PCM is loaded on the sealed surplus part of the battery cell in a state in which the PCM is received in the module case such that the PCM is electrically connected to the electrode terminals of the battery cell.