Battery Pack Protection Circuit Module Nesting
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Solution Overview
Problem
Conventional battery packs face challenges in maximizing battery capacity within a given size due to the height of protection circuit modules and insulating plates, which can lead to inefficiencies in packaging and reduced overall capacity.
Innovation Solution
The battery pack design incorporates a protection circuit module with a protection member that is attached at a lower height than the holder's edges, allowing for a thinner profile, and an insulating plate with a protrusion that reduces the pack's size while increasing the bare cell's capacity, without altering the external dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protection circuit module and insulating plate are designed with sufficient height for protection and insulation, then reliability is improved, but the overall pack size increases and battery capacity is reduced
Solution Approach 1:
The protection circuit module is nested within the holder, with its upper surface positioned below the upper edges of the holder. The insulating plate is nested within the battery pack structure, with its upper surface positioned below the upper surface of the protection circuit module. This nested arrangement allows sufficient protection and insulation while minimizing the overall pack height.
Solution Approach 2:
The patent utilizes vertical layering to create distinct height levels for different components. The holder edges extend higher than the protection circuit module, and the insulating plate extends higher than the bare cell but lower than the protection circuit module. This dimensional stratification optimizes space utilization while maintaining protective functions.
2Reliability
If the protection circuit module and insulating plate are designed with sufficient height for protection and insulation, then reliability is improved, but the bare cell capacity is reduced
Solution Approach 1:
By nesting the protection circuit module and insulating plate within the vertical space of the battery pack rather than allowing them to extend to the full height, more vertical space becomes available for the bare cell. The bare cell can extend from the bottom of the pack up to the level of the insulating plate, maximizing its volume and capacity.
Solution Approach 2:
The patent creates a vertical stacking arrangement where the bare cell, insulating plate, protection circuit module, and holder are arranged at different height levels. This allows the bare cell to occupy the maximum possible vertical space while the protective components maintain sufficient height for their functions.
Data Source
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AI summary
A battery pack includes: a bare cell including an electrode terminal on a first surface thereof; a holder at the first surface and including a fixing groove at an upper surface thereof; a protection circuit module at the fixing groove and electrically connected to the bare cell; and a protection member attached to the protection circuit module. The protection member is attached to an upper surface of the protection circuit module, and the upper surface is at a lower height than upper edges of the fixing groove. An upper surface of the protection member is at a height that is the same as or lower than a height of edges of the holder.