Battery Pack Top Case Recesses Prevent Welding Interference
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Solution Overview
Problem
Existing battery pack assembly processes are prone to assembly errors and defects, particularly in the coupling of the top case to the battery cell, due to welding issues.
Innovation Solution
The battery pack design incorporates a top case with recessed interference preventing portions and position determination portions to prevent interference during welding and ensure accurate alignment, along with a protection circuit module (PCM) within the top case, allowing for secure and precise electrical connections between the electrode assembly and the protection circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a top case is coupled to a battery cell during assembly, then the protection circuit module can be electrically connected to the electrode assembly, but assembly errors and welding defects may occur due to interference between components
Solution Approach 1:
The patent extracts the interference-preventing function from the welding process itself and incorporates it into the top case structure through recessed portions. These recesses create clearances that extract the source of interference (component overlap) from the assembly, allowing welding to proceed without obstruction while maintaining reliable electrical connections between the PCM and electrode assembly.
Solution Approach 2:
The recessed interference-preventing portions are pre-formed in the top case structure before assembly occurs. This preliminary design feature ensures that when components are brought together during assembly, the welding area is already cleared of potential obstructions, preventing welding defects before they can occur rather than requiring corrective actions after assembly.
2Ease of manufacture
If components are assembled without interference prevention features, then assembly process is simpler, but assembly errors and defects increase
Solution Approach 1:
The top case structure provides self-service by incorporating recessed interference-preventing portions that automatically prevent assembly errors during the coupling process. The design itself performs the function of error prevention without requiring external intervention or complex assembly procedures, maintaining both ease of manufacture and high assembly precision.
Solution Approach 2:
Rather than making the entire top case structure more complex, the patent applies local quality by adding recessed portions only at specific locations where interference occurs during welding. This localized modification maintains the overall simplicity of the assembly process while precisely addressing the areas where manufacturing precision is critical.
Data Source
AI summary
A battery pack including a battery cell including an electrode assembly arranged within a can and an electrode terminal electrically connected to the electrode assembly, the can having an opening sealed by a cap plate, a top case attached to the battery cell at a top portion of the battery cell, the top case having an inner space and a protective circuit module including a protection circuit board arranged within said inner space of said top case and electrically connected to the electrode assembly, wherein the top case includes a top portion opposite from the electrode assembly and first and second pairs of opposed sides, the first pair of opposed sides having an edge, a portion of the edge has a recessed interference preventing portion, the recessed interference preventing portion corresponds to a location of a weld connecting an electrode tap to the electrode terminal.