Battery Pack PCM Mounting on Sealed Surplus Portion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing secondary battery pack assembly process is complex and costly due to the need for multiple insulative tapes, which also compromises mechanical strength and dimensional stability, and exposes electrode terminals, while conventional internal type structures suffer from manufacturing inefficiencies and aesthetic issues.
Innovation Solution
A secondary battery pack design featuring a protection circuit module (PCM) with a protection circuit board mounted to the outer circumference of a battery cell, surrounded by a frame that provides electrical insulation and structural support, reducing the number of parts and simplifying assembly, while preventing terminal exposure and enhancing stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulative tapes are used to achieve safe connection between the safety element and the battery cell, then electrical insulation is improved, but the assembly process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent combines multiple insulative tapes and the sealed surplus portion into a single integrated insulative structure. The sealed surplus portion itself is utilized as the insulative component, eliminating the need for separate insulative tapes. This merging reduces the number of parts and simplifies the assembly process while maintaining electrical insulation functionality.
Solution Approach 2:
The sealed surplus portion serves multiple functions: it provides electrical insulation between the safety element and the battery cell, maintains structural integrity, and eliminates the need for additional insulative components. By making the sealed surplus portion multi-functional, the patent reduces overall device complexity while preserving reliability.
2Reliability
If multiple insulative tapes are used to achieve safe connection, then electrical insulation is improved, but manufacturing cost is increased
Solution Approach 1:
The patent merges the insulation function into the sealed surplus portion, eliminating the need for separate insulative tapes. This reduction in part count directly lowers manufacturing costs while maintaining the required electrical insulation performance.
Solution Approach 2:
The sealed surplus portion serves its own additional function as an insulative component, eliminating the need for separate insulative tapes. This self-service approach reduces part count and manufacturing cost while maintaining insulation performance.
3Reliability
If insulative tapes are used to isolate the PCM, then electrical insulation is improved, but dimensional stability is greatly lowered due to low mechanical strength
Solution Approach 1:
The patent combines the insulation function with the sealed surplus portion, which is inherently structurally integrated with the battery cell. This integration ensures that the insulative structure maintains dimensional stability and mechanical strength, unlike separate insulative tapes that can deform under external impact.
4Productivity
If the battery cell is partially surrounded by a frame with PCM mounted on outer circumference, then capacity per unit volume is improved, but the PCM and electrode terminals need protection from external impact and exposure
Solution Approach 1:
The patent combines the sealed surplus portion with the insulative structure to create an integrated protective covering. This unified structure simultaneously protects the PCM from external impact and prevents electrode terminal exposure, while maintaining the compact design that maximizes capacity per unit volume.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed herein is a secondary battery pack including a battery cell having an anode terminal and a cathode terminal formed at one face having a sealed surplus portion and a protection circuit module (PCM) electrically connected to the battery cell via the anode terminal and the cathode terminal, wherein the PCM includes a board having a protection circuit formed thereon, the board being provided with an anode terminal connection part and a cathode terminal connection part connected to the anode terminal and the cathode terminal, respectively, the board is coupled to the anode terminal and the cathode terminal of the battery cell via the anode terminal connection part and the cathode terminal connection part and is mounted to the sealed surplus portion of the battery cell, and the secondary battery pack further includes a frame mounted to the PCM and the battery cell so as to surround the PCM and the battery cell.