Battery Pack Support Plate Layout for PCB Force Protection
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Solution Overview
Problem
Existing battery packs face challenges in protecting the protective circuit module from damage due to external forces, particularly during the assembly process when excessive force is applied.
Innovation Solution
A battery pack design that includes a support plate with partial support portions spaced apart in a horizontal direction, supporting a substrate with protective elements, and featuring stepped structures to disperse and prevent excessive force from reaching the substrate and protective elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a support plate is added to protect the substrate, then the mechanical strength and durability are improved, but the device complexity increases
Solution Approach 1:
The support plate is divided into multiple partial support portions (first, second, and third support portions) that are spatially separated. This segmentation allows the support plate to provide targeted protection at specific locations while maintaining overall structural integrity, resolving the contradiction by distributing support functions across multiple segments rather than requiring a single complex structure.
Solution Approach 2:
Different regions of the support plate have different thicknesses and support capabilities. The first and second support portions have greater thickness for enhanced protection at critical areas, while the third support portion has reduced thickness where full support is not needed. This local differentiation optimizes mechanical strength where required while minimizing unnecessary material and complexity elsewhere.
2Reliability
If the support plate covers the entire substrate, then the protection against external forces is improved, but the manufacturing precision and assembly difficulty increase
Solution Approach 1:
The support plate is divided into multiple discrete partial support portions rather than forming a continuous covering layer. This segmentation simplifies the manufacturing process and assembly requirements, as each portion can be independently formed and positioned, reducing the precision demands compared to creating a single continuous support structure that fully covers the substrate.
Solution Approach 2:
The support plate provides support only at specific critical locations (first and second support portions at opposite ends and third support portion at the protective element position) rather than uniformly across the entire substrate. This partial support approach achieves adequate protection reliability while significantly reducing manufacturing complexity and assembly precision requirements compared to full-coverage support.
3Strength
If thicker support portions are used to prevent damage, then the mechanical strength is improved, but the device complexity and material usage increase
Solution Approach 1:
The support plate features variable thickness with the first and second support portions having greater thickness for enhanced mechanical strength at critical support locations, while the third support portion has reduced thickness where full support is not required. This local quality differentiation provides necessary protection strength while minimizing overall material usage and structural complexity.
Solution Approach 2:
The support plate is segmented into multiple portions with different thickness characteristics. This segmentation allows each portion to be optimized independently for its specific function, providing thick reinforcement only where mechanically necessary while using thinner sections elsewhere, thereby reducing overall device complexity and material requirements while maintaining adequate protection strength.
Data Source
AI summary
Provided is a battery pack. The battery pack comprises a battery cell extending in a vertical direction and comprising a plurality of electrode tabs, a substrate on which a protective element is arranged, the substrate being fixed to an upper end of the battery cell and electrically connected to the plurality of electrode tabs, and a support plate that is disposed between the battery cell and the substrate and that supports the substrate, wherein the support plate comprises at least two partial support portions that are spaced apart from each other in a horizontal direction crossing the vertical direction.