Battery Pack Circuit Module Resin Insulation
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Solution Overview
Problem
Conventional battery packs face challenges in space utilization and manufacturing complexity, leading to increased costs due to the need for additional fixing members and dummy tabs in both horizontal and vertical installations.
Innovation Solution
A battery pack design featuring a circuit module with an insulation substrate, electrical elements, and a resin layer that includes a heat discharge hole, which simplifies the manufacturing process and reduces costs by eliminating the need for additional fixing members and dummy tabs, while enhancing space utilization through a compact and slim structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cell is spaced at a predetermined distance from the protection circuit module to prevent short circuit, then safety is improved, but volume and capacity occupied by the cell are reduced
Solution Approach 1:
An insulating resin layer is introduced as an intermediary substance between the cell and protection circuit module. This resin layer provides both electrical insulation to prevent short circuits and mechanical spacing to maintain safety, while allowing the components to be positioned closer together than traditional air-gap designs, thereby improving space utilization.
2Stability of the object's composition
If additional fixing members are used to stably seat the protection circuit module in horizontal installation, then structural stability is improved, but manufacturing process complexity and cost increase
Solution Approach 1:
The fixing function is merged into the insulating resin layer itself. The resin layer is molded to directly contact and secure the protection circuit module to the cell, eliminating the need for separate fixing members such as clips, adhesives, or mechanical fasteners, thereby simplifying the manufacturing process.
Solution Approach 2:
The resin layer's physical properties (viscosity during molding, curing characteristics) are utilized to achieve stable fixation. By controlling the molding parameters and resin characteristics, the protection circuit module is firmly secured without requiring additional mechanical fixing components.
3Reliability
If an insulating dummy tab is used to separate the cell from the protection circuit module in vertical installation, then insulation and balance are improved, but manufacturing process complexity and cost increase
Solution Approach 1:
The insulation and spacing functions traditionally performed by a dummy tab are merged into the insulating resin layer. The resin layer is molded to extend between the cell and protection circuit module, providing both electrical insulation and physical separation, thereby eliminating the need for separate dummy tab components.
Solution Approach 2:
The dummy tab component is extracted from the assembly by integrating its functions into the resin layer. This eliminates the need for a separate insulating tab piece, reducing part count and manufacturing complexity while maintaining the necessary insulation and spacing functions.
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
The design achieves improved space utilization and reduced manufacturing costs by simplifying the manufacturing process, allowing for a more compact and stable battery pack without the need for additional fixing members or dummy tabs.
Implementation Method 1
the resin layer includes a heat discharge hole in communication with the electrical element
Data Source
Figure 1a
Figure 1b
Figure 1c~1d
AI summary
A battery pack, including a cell, a circuit module electrically coupled to the cell, the circuit module including an insulation substrate, an electrical element on the insulation substrate, and at least one resin layer surrounding the electrical element, and a cover surrounding the circuit module and coupling the circuit module to the cell.