Battery Protective Structure for Flexible PCB Impact Resistance
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Solution Overview
Problem
Existing batteries face issues with damage to elements such as the protection board and flexible printed circuit board due to impacts during drop tests or similar conditions, leading to potential failure and reduced energy density.
Innovation Solution
A battery design featuring an injection-molded plastic structure that encloses critical components like the protection board and flexible printed circuit board, with a groove allowing for bending and position adjustment of the circuit board, ensuring a minimum groove width of 2 mm and depth of 0.5 mm to protect and accommodate the circuit board, reducing the overall battery volume and increasing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elements such as the protection board are disposed on the top of the cell, then the cell is protected from damage or explosion risk caused by abnormal conditions, but the elements may be damaged due to impacts during drop tests or similar conditions
Solution Approach 1:
The patent applies beforehand cushioning by providing a protective structure that includes a cushioning layer or shock-absorbing elements positioned to protect the protection board and flexible printed circuit board from impact damage during drop tests or similar conditions, while maintaining their protective function against abnormal conditions
2Stability of the object's composition
If the protection board and flexible printed circuit board are fixed rigidly on the cell, then structural stability is improved, but the ability to adjust the position of the output end is reduced
Solution Approach 1:
The patent applies dynamics by designing the protective structure with flexible support elements or adjustable mounting mechanisms that allow the output end position of the flexible printed circuit board to be adjusted while maintaining structural stability during normal operation, enabling adaptation to different assembly requirements
3Reliability
If the battery components are arranged to provide adequate protection and adjustment space, then reliability and adaptability are improved, but the overall battery volume increases
Solution Approach 1:
The patent applies nested doll by integrating the protective structure within the existing battery housing space, positioning the protection board and flexible printed circuit board in a nested arrangement where the protective elements are incorporated into the available volume without significantly increasing the overall battery dimensions
Data Source
AI summary
A battery, including a cell, a protection board and an injection-molded plastic structure. The injection-molded plastic structure encloses at least a tab, a top sealing edge, a main board and a portion of a flexible printed circuit board, an output end of the flexible printed circuit board is located outside the injection-molded plastic structure, and a groove is formed on the injection-molded plastic structure at a position corresponding to where the output end extends, with at least a portion of the output end being located within the groove. The groove has a minimum groove width of not less than 2 mm in a first direction, and has a groove depth of not less than 0.5 mm in a second direction. In this way, the injection-molded plastic structure provides effective protection for elements such as the protection board, and ensures a sufficient space for movement of the flexible printed circuit board.