Insulative Case Mounting for Battery PCM Assembly
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Solution Overview
Problem
The assembly process of secondary battery packs is complex due to the need for multiple insulative tapes to ensure electrical isolation and protection of the protection circuit module (PCM), leading to increased manufacturing costs and potential mechanical weaknesses.
Innovation Solution
A secondary battery pack design where the protection circuit module is housed in an electrically insulative case, mounted to the outer circumference of the battery cell, reducing the number of parts and simplifying assembly, while providing structural stability and protection against external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulative tapes are used to ensure electrical isolation and protection of the PCM, then electrical safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple insulative functions into a single integrated insulative case structure. The case simultaneously provides electrical isolation, mechanical protection, and structural support for the PCM, eliminating the need for separate insulative tapes and simplifying the assembly process while maintaining electrical safety
Solution Approach 2:
The insulative case serves multiple functions: it provides electrical insulation, mechanical protection against external impacts, structural support for the PCM, and prevents electrode terminal exposure. This multi-functional design replaces several separate components with one unified structure
2Reliability
If multiple insulative tapes are used to protect the PCM, then electrical isolation is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the functions of multiple insulative tapes into a single insulative case structure, reducing the number of parts and associated manufacturing costs while maintaining effective electrical isolation
3Reliability
If insulative tapes are used to isolate the PCM, then electrical safety is improved, but mechanical strength decreases due to low mechanical strength of tapes
Solution Approach 1:
The patent combines electrical insulation and mechanical protection functions into a single insulative case structure that provides both electrical safety and enhanced mechanical strength, eliminating the weakness of using separate insulative tapes
Solution Approach 2:
The insulative case appears to be constructed from composite materials that provide both electrical insulation properties and high mechanical strength, simultaneously achieving electrical safety and structural durability
4Device complexity
If the PCM is mounted to the outer circumference of the battery cell, then device complexity is reduced, but the battery pack capacity may be reduced
Solution Approach 1:
The patent utilizes the outer circumference surface area of the battery cell for mounting the PCM, effectively using available space in a different dimensional arrangement that does not compromise the internal battery capacity
Data Source
AI summary
A battery pack including a battery cell having an anode and cathode terminal at one face having a sealed surplus portion and a protection circuit module (PCM) connected to the cell via the anode and cathode terminal, the PCM including a board having a protection circuit thereon, the board being provided with an anode and cathode terminal connection part connected to the anode and cathode terminal, respectively, and a PCM case configured to receive the board through an open face thereof so that the PCM case surrounds the board. The board is coupled to the anode and cathode terminal of the cell via the anode and cathode terminal connection part, the board is disposed in the PCM case in a state in which the board is parallel to the cell, and the PCM case, in which the board is disposed, is mounted to the sealed surplus portion of the cell.