Battery Pack Top Cap with Hook Protrusions for PCB Protection
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Solution Overview
Problem
Conventional battery packs face challenges in protecting the printed circuit board (PCB) from foreign substances and have increased lead times due to manual assembly and open-top designs, which can lead to safety risks and inefficiencies.
Innovation Solution
A battery pack design featuring a top cap with hook protrusions that is press-fitted onto the PCB, providing a closed surface to prevent foreign substances from entering and allowing for automated assembly, reducing production time and enhancing protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an open-top upper case design is used to protect the PCB, then the PCB is protected from external impacts, but foreign substances can be introduced into the upper case
Solution Approach 1:
The patent employs a thin film insulating tape to seal the open-top upper case, creating a closed structure that prevents foreign substance introduction while maintaining the protective function against external impacts. The flexible thin film adapts to the case structure and provides effective sealing.
2Reliability
If manual mounting of insulation tape is used to protect the PCB, then electrical insulation is provided, but the lead time for production increases
Solution Approach 1:
The patent combines the insulation function and the sealing function into a single insulating tape component. This multi-functional design eliminates the need for separate insulation tape application steps, enabling automated assembly and significantly reducing production lead time while maintaining electrical insulation reliability.
Solution Approach 2:
The insulating tape serves multiple functions simultaneously: it provides electrical insulation for the PCB, seals the open-top upper case to prevent foreign substance introduction, and facilitates automated assembly. This multi-functionality resolves the contradiction between reliability and productivity.
3Reliability
If insulation tape is attached to protect the PCB, then electrical insulation is maintained, but the process is troublesome and lacks additional protective functions
Solution Approach 1:
The patent merges the insulation function with the sealing function in a single insulating tape component. This integration simplifies the assembly process by eliminating multiple separate steps while providing both electrical insulation and protection against foreign substances, thereby reducing device complexity.
Data Source
Figure 1
Figure 2
Figure 3(a)~3(d)
AI summary
The present invention relates to a battery pack and a method for manufacturing the same, and more particularly, to a battery pack including a top cap having a hook protrusion for protecting a PCB connected to a pouch-type battery cell and a method for manufacturing the same.