Battery Pack Terminal and Insulation Layout for Short-Circuit Prevention
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Solution Overview
Problem
Existing battery packs face challenges in efficiently arranging and connecting unit batteries to minimize space and prevent short-circuits while ensuring effective protection against overcharging, over-discharging, and overheating.
Innovation Solution
A battery pack design featuring unit batteries arranged side by side with exposed cap plates, each equipped with first and second terminals that connect directly to a protection circuit module, which includes a circuit board and protection devices, allowing for parallel and series connections without an intermediate member, and utilizing insulation to prevent short-circuits between adjacent batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If unit batteries are arranged side by side with cap plates exposed in the same direction, then the number of parts is reduced and space is minimized, but the risk of short-circuit between adjacent batteries increases
Solution Approach 1:
The battery pack is segmented into multiple independent unit batteries, each with its own cap plate exposed in the same direction. This segmentation allows for reduced part count while maintaining safety through proper spacing and insulation between segments.
Solution Approach 2:
An insulating structure is introduced as an intermediary element between adjacent unit batteries. This mediator prevents direct contact between cap plates of neighboring batteries, eliminating the short-circuit risk while allowing the compact side-by-side arrangement to proceed.
2Volume of moving object
If terminals are directly connected to protection circuit module without intermediate members, then space is minimized and connection efficiency is improved, but the complexity of preventing short-circuits increases
Solution Approach 1:
The terminal connection structure is merged directly with the protection circuit module, eliminating intermediate connectors. This merging reduces space requirements while the integrated design simplifies the overall connection architecture rather than complicating it.
Solution Approach 2:
The protection circuit module serves multiple functions: it provides electrical connection, protection against overcharging/discharging, and integration with the terminal structure. This multi-functionality reduces the need for separate intermediate components.
3Ease of manufacture
If cap plates are exposed in the same direction for all unit batteries, then assembly is simplified and space is minimized, but insulation requirements between adjacent batteries become more critical
Solution Approach 1:
The insulating structure is strategically positioned at specific locations where adjacent cap plates are in close proximity. This localized insulation approach maintains the simplified same-direction exposure arrangement while addressing insulation requirements only where critically needed.
Solution Approach 2:
The insulating structure is pre-installed or integrated into the battery pack design before final assembly. This preliminary action ensures that insulation is already in place to prevent short-circuits, making the assembly process simpler and more reliable.
Data Source
AI summary
A battery pack includes a plurality of unit batteries arranged side by side in a first direction, each unit battery including a can accommodating an opening including an electrode assembly having a first electrode plate, a second electrode plate, and a separator between the electrode plates, and a cap plate sealing the opening. The plurality of unit batteries may be arranged side by side in the first direction with all the cap plates exposed in the same direction. The battery pack may further include a protection circuit module adjacent to the cap plate with a circuit board extending in the first direction and a protection device coupled to it, wherein each unit battery further includes a first terminal on a first area of the cap plate and a second terminal on a second area of the cap plate, each coupled to the unit battery and the protection circuit module.