Battery Pack Wireless Charging Coil Nesting
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Solution Overview
Problem
Existing battery packs face challenges in increasing capacity while minimizing size, especially with the integration of a charging coil for wireless charging, which complicates assembly and can interfere with protection circuit modules, and requires a reduction in the number of components at the battery cell's top for stability and safety.
Innovation Solution
A compact battery pack design with an insulative pack frame and top cap that surrounds the protection circuit module, allowing for efficient mounting and non-contact charging via an electromagnetic induction type charging coil, while using a shielding member to minimize interference and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a charging coil is installed in the battery pack for wireless charging, then wireless charging capability is achieved, but the battery pack size increases and assembly becomes complicated
Solution Approach 1:
The charging coil is mounted on the side surface of the battery cell, nesting it within the existing battery pack structure rather than adding external components. This allows wireless charging capability to be integrated without significantly increasing the overall battery pack volume.
Solution Approach 2:
Instead of placing the charging coil in the traditional top or bottom position that would increase height, the coil is positioned on the side surface of the battery cell. This dimensional change allows wireless charging functionality to be added while maintaining a compact form factor.
2Reliability
If multiple components are mounted at the top of the battery cell for safety and electrical connection, then safety and electrical connection are ensured, but the number of components increases and assembly becomes complicated
Solution Approach 1:
The top cap is designed to integrate multiple functions: it provides electrical insulation, mechanical support for the protection circuit module, and structural closure for the battery cell. By combining these functions into a single component, the number of separate parts is reduced while maintaining safety and electrical connection reliability.
Solution Approach 2:
The top cap serves multiple purposes simultaneously: it acts as an insulator, a mounting structure for the PCM, and a protective cover. This multi-functionality reduces the need for separate dedicated components for each function, simplifying the overall assembly.
3Device complexity
If the battery pack structure is optimized to reduce components at the top of the battery cell, then assembly is simplified and capacity is increased, but stable coupling among members may be compromised
Solution Approach 1:
The top cap is designed with a curved surface that conforms to the cylindrical shape of the battery cell. This curved geometry provides stable contact and coupling between the top cap and the battery cell, ensuring mechanical stability while maintaining a compact structure.
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 a compact structure with increased battery capacity, simplified assembly, and non-contact charging without size increase or interference issues, enhancing safety and efficiency.
Implementation Method 1
an electromagnetic induction type charging coil mounted at at least one main surface of the battery cell
Implementation Method 2
a shielding member interposed between the battery cell and the charging coil
Data Source
AI summary
Disclosed herein is a battery pack including a battery cell having a first electrode terminal and a second electrode terminal, a protection circuit module (PCM) including a protection circuit board (PCB), at which a safety element is mounted, the PCB having a protection circuit, and connection members (A and B) connected respectively to the first and second electrode terminals of the battery cell, an electrically insulative pack frame configured to have a structure in which the battery cell is mounted in the pack frame, the pack frame having an insulative mounting part, at a top of which the PCB is mounted, an electrically insulative top cap mounted at a top of the battery cell while surrounding the PCM, an electromagnetic induction type charging coil mounted at at least one main surface of the battery cell, the charging coil being connected to the PCM, and a shielding member interposed between the battery cell and the charging coil.