Insulative Case for Secondary Battery Pack PCM
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Solution Overview
Problem
The existing secondary battery pack assembly process is complex, costly, and prone to mechanical damage due to the use of multiple insulative tapes, which also compromises structural stability and exposes electrode terminals.
Innovation Solution
A secondary battery pack design where a protection circuit module is housed within an electrically insulative case, mounted to the outer circumference of the battery cell, reducing the number of parts and using an assembly-type fastening structure to secure the case, thereby protecting the circuit board and preventing terminal exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulative tapes are used to connect the protection circuit board to the battery cell, then electrical insulation is achieved, but the assembly process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent combines multiple insulative tapes and insulating structures into a single integrated insulative case that houses the protection circuit board. This case is formed as one piece with built-in insulating walls and structures, eliminating the need to attach multiple separate tapes during assembly while maintaining comprehensive electrical insulation between the PCB and battery cell.
Solution Approach 2:
The insulative case is designed with segmented internal structures including insulating walls, partitions, and stepped portions that create distinct insulated zones. These internal segments provide targeted insulation at specific locations where electrical contact risks exist, while the overall case remains a single integrated component for simplified assembly.
2Reliability
If multiple insulative tapes are used to secure the protection circuit board, then electrical isolation is achieved, but structural stability decreases due to low mechanical strength of tapes
Solution Approach 1:
The patent merges the functions of electrical insulation and mechanical securing into a single insulative case structure. The case provides both electrical isolation through its insulating material and mechanical strength through its rigid or semi-rigid construction, replacing the weak mechanical properties of multiple tapes with a unified structurally sound component.
Solution Approach 2:
The insulative case is made from composite materials that combine high electrical insulation properties with adequate mechanical strength. The material composition and structural design provide both dielectric protection and the mechanical robustness needed to withstand external impacts and maintain dimensional stability.
3Reliability
If multiple insulative tapes and parts are used to connect the protection circuit board, then electrical safety is improved, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent consolidates multiple separate insulative components (tapes, insulators, supports) into a single integrated insulative case. This case incorporates all necessary insulating features, mounting structures, and protective elements in one manufacturable component, reducing the total part count and simplifying the manufacturing and assembly processes while maintaining comprehensive electrical safety.
4Device complexity
If the protection circuit board is exposed without adequate insulation, then assembly is simplified, but electrode terminals become exposed and electrical hazards increase
Solution Approach 1:
The insulative case serves multiple functions simultaneously: it provides electrical insulation to prevent hazards, houses and protects the protection circuit board, provides mechanical support and positioning, and prevents exposure of electrode terminals. This multi-functional design achieves comprehensive safety without increasing assembly complexity.
Data Source
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AI summary
Disclosed herein is a secondary battery pack including a battery cell having a cathode terminal and an anode terminal formed at one face having a sealed surplus portion and a protection circuit module (PCM) electrically connected to the battery cell via the cathode terminal and the anode terminal, wherein the PCM includes a board having a cathode terminal connection part connected to the cathode terminal and an anode terminal connection part connected to the anode terminal, and a first case and a second case each having an open face, the first case and the second case being coupled to each other so that the open faces of the first case and the second case are opposite to each other, the board being disposed in a space defined in the first case and the second case through the open faces. The first case and the second case, in which the board is disposed, are mounted to the sealed surplus portion of the battery cell.