Abstract:
A design for a battery pack that provides for a foolproof and easy assembly process, especially during when the protection circuit module is inserted into and combined with the battery case. The protection circuit module includes a circuit substrate with driving circuits arranged on both sides thereof. This circuit substrate is inserted between a first barrier rib of the battery case and a second barrier rib and arranged in parallel thereto. Supporting barrier ribs extending orthogonal from the barrier ribs towards the circuit substrate have a rounded top edge to guide the circuit substrate into the proper location in the battery case. The height of these supporting barrier ribs are formed at least as tall as the barrier ribs to prevent the circuit substrate or the driving circuits from contacting the barrier ribs during the insertion process.

Description:
CLAIM OF PRIORITY 
       [0001]    This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application earlier filed in the Korean Intellectual Property Office on the 4 Jan. 2012 and there duly assigned Serial No. 10-2012-0001008. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to a battery pack having a structure that provides for easier and more foolproof assembly. 
         [0004]    2. Description of the Related Art 
         [0005]    A secondary battery among battery cells capable of charging and discharging is widely used as an energy source in smartphones, laptops, electric tools and electric vehicles. 
         [0006]    On the other hand, the structure thereof may be easily varied according to the kinds of apparatuses being powered. For example, when the secondary battery is used as an energy source for a laptop computer, it is possible to configure a plurality of secondary batteries into a battery pack. 
         [0007]    In general, the battery pack may include a plurality of secondary batteries, a battery case housing the same, and a protection circuit module. The protection circuit module prevents overcharging and overdischarging of the secondary batteries. 
         [0008]    Typically, the protection circuit module may include the circuit substrate, charging and discharging switches mounted on the circuit substrate, and a number of circuit components driving the same. Further, the protection circuit module and the secondary batteries in the battery pack are arranged so that they are spaced-apart from each other, thereby preventing damage to the protection circuit module caused by external forces acting on the secondary batteries. 
       SUMMARY OF THE INVENTION 
       [0009]    An advantage of some aspects of the present invention is that it provides a battery pack having a structure capable of more easily assembling a protection circuit module thereto. 
         [0010]    According to one aspect of the present invention, there is provided a battery pack that includes a first case having a bottom portion, first and second housing spaces spaced-apart from each other by a dividing barrier rib having a first height and extending from the bottom portion, at least one battery cell arranged within the first housing space, a protection circuit module arranged within the second housing space and a pair of supporting ribs arranged within the second housing space, and supporting the protection circuit module from the dividing barrier rib, at least one of the supporting ribs extending from the bottom portion and having a height of at least the first height. Each of the pair of supporting ribs may have a top edge that is rounded. 
         [0011]    The first case may also include an auxiliary barrier rib extending from the bottom portion, spaced-apart from the dividing barrier rib, and defining the second housing space together with the dividing barrier rib. The pair of supporting ribs may include a first supporting rib supporting the protection circuit module from the dividing barrier rib while having a height of at least the first height and a second supporting rib facing and being spaced-apart from the first supporting rib while supporting the protection circuit module from the auxiliary barrier rib. The dividing barrier rib may be arranged closer to the at least one battery cell than the auxiliary barrier rib. The first supporting rib may be arranged closer to the at least one battery cell than the second supporting rib. The height of the first supporting rib may be greater than the height of the second supporting rib. The first supporting rib may extend towards the protection circuit module from the dividing barrier rib, and the second supporting rib may extend toward the protection circuit module from the auxiliary barrier rib. 
         [0012]    The protection circuit module may include a circuit substrate and a driving circuit mounted on the circuit substrate, the first supporting rib contacting both the circuit substrate and the dividing barrier rib, the second supporting rib contacting both the circuit substrate and the auxiliary barrier rib. A length that the first supporting rib extends from the dividing barrier rib may be greater than a thickness of the driving circuit. The driving circuit may include a first driving circuit mounted on a surface of the circuit substrate that faces the dividing barrier rib. The driving circuit may also include a second driving circuit mounted on a surface of the circuit substrate that faces the auxiliary barrier rib. Each of the first and second supporting ribs may include a guide portion having a round shape at a top end thereof. The battery pack may also include a second case coupled to the first case and covering the first and second housing spaces. 
         [0013]    The pair of supporting ribs may include a first supporting rib supporting the protection circuit module from the dividing barrier rib while having a height of at least the first height and a second supporting rib facing and being spaced-apart from the first supporting rib while supporting the protection circuit module from the auxiliary barrier rib and having a same height as the auxiliary barrier rib. The auxiliary barrier rib may be arranged in parallel to the dividing barrier rib. The protection circuit module may include a circuit substrate and a driving circuit mounted on the circuit substrate, the circuit substrate may be arranged between the auxiliary barrier rib and the dividing barrier rib and be in parallel to each of the auxiliary barrier rib and the dividing barrier rib. The first supporting rib may extend in a direction that is orthogonal to each of the dividing barrier rib and the bottom portion of the first case, and the second supporting rib may extend in a direction that is orthogonal to each of the auxiliary barrier rib and the bottom portion of the first case. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which like reference symbols indicate the same or similar components, wherein: 
           [0015]      FIG. 1  is an exploded perspective view of a battery pack according to an embodiment of the present invention; 
           [0016]      FIG. 2  is a partial prospective view magnifying a first case, a protection circuit module and battery cells of the battery pack of  FIG. 1 ; 
           [0017]      FIG. 3A  is an exploded prospective view showing the first case, the protection circuit module and the battery cells of  FIG. 2  prior to being combined; 
           [0018]      FIG. 3B  is a cross-sectional view taken by line I-I′ of  FIG. 3A ; and 
           [0019]      FIG. 4  is a cross-sectional view of a battery pack according to another embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    In the following detailed description, only certain exemplary embodiments of the present invention have been shown and described, simply by way of illustration. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive. In addition, when an element is referred to as being “on” another element, it can be directly on the another element or be indirectly on the another element with one or more intervening elements interposed therebetween. Also, when an element is referred to as being “connected to” another element, it can be directly connected to the another element or be indirectly connected to the another element with one or more intervening elements interposed therebetween. Hereinafter, like reference numerals refer to like elements. 
         [0021]    Hereinafter, the embodiment of the present invention will be described in detail with reference to the attached drawings. although the preferred embodiments of the present invention are shown and described above, the present invention is not limited to above-described specific embodiment and is variously modified by one skilled in the art without the gist of the present invention claimed in the claim, such that the modified embodiment is not to be understood separately from technical ideas or views of the present invention. On the other hand, the drawings related to the embodiments will be somewhat simplified or exaggerated for a clear description, and like reference numerals refer to like components. 
         [0022]    Turning now to  FIGS. 1 and 2 ,  FIG. 1  is an exploded perspective view of a battery pack  100  according to a first embodiment of the present invention, and  FIG. 2  is a partial prospective view of a first case, a protection circuit module and battery cells of the battery pack of  FIG. 1 . Referring to  FIGS. 1 and 2 , battery pack  100  includes a battery case having a first case  30  and a second case  60 , a plurality of battery cells  5 , a protection circuit module  40  and a pair of supporting ribs  70 . The first case  30  has a first housing space A 1  housing the plurality of battery cells  5  and covering the bottom of the plurality of battery cells  5  and a second housing space A 2  housing the protection circuit module  40 . Further, the second case  60  is coupled to the first case  30 , and covers a top of the battery cells  5  housed within the first case  30 . 
         [0023]    In more detail, the first case  30  includes a bottom portion  10 , a dividing barrier rib  20  and an auxiliary barrier rib  25 . The dividing barrier rib  20  included on the bottom portion  10  is extended along one side of the bottom portion  10 . In the first case  30 , the dividing barrier rib  20  is a component dividing the first housing space A 1  and the second housing space A 2  so that the first housing space A 1  and the second housing space A 2  are spaced-apart from each other by the dividing barrier rib  20 . 
         [0024]    The auxiliary barrier rib  25  on the bottom portion  10  is spaced-apart from the dividing barrier rib  20 , extends along one side of the bottom portion  10  and defines the second housing space A 2  together with the dividing barrier rib  20 . Further, since the auxiliary barrier rib  25  on the bottom portion  10  is positioned closer to an outside of the battery pack  100  than the dividing barrier rib  20 , the dividing barrier rib  20  is closer to the battery cells  5  than the auxiliary barrier rib  25 . 
         [0025]    A number of battery cells  5  are housed within the first housing space A 1 . In the embodiments of the present invention, each of the battery cells  5  may be chargeable and dischargeable secondary batteries. The protection circuit module  40  is housed within the second housing space A 2 , is electrically connected to the battery cells  5 , and prevents the battery cells  5  from being overcharged and over discharged. 
         [0026]    In the embodiments of the present invention, the protection circuit module  40  may include a circuit substrate  46 , first to fourth driving circuits  41 ,  42 ,  43  and  44 , and a connector  48 . The circuit substrate  46  may be a printed circuit board, and the protection circuit module  40  may be electrically connected to another external apparatus through the connector  48  which is mounted on the circuit substrate  46 . Further, the first to fourth driving circuits  41 ,  42 ,  43 , and  44 , which are mounted on the circuit substrate  46 , may include a plurality of charging switches, discharging switches and electronic devices driving the same. 
         [0027]    On the other hand, in the embodiments of the present invention, the first and second driving circuits  41  and  42  may be spaced-apart from each other and be arranged on one surface of the circuit substrate  46  while the third and fourth driving circuits  43  and  44  may also be spaced-apart from each other and be arranged on the other surface of the circuit substrate  46 . Thus, the first and second driving circuits  41  and  42  are arranged between the circuit substrate  46  and the auxiliary barrier rib  25  and face the auxiliary barrier rib  25 , and the third and fourth driving circuits  43  and  44  are arranged between the circuit substrate  46  and the dividing barrier rib  20  and face the driving barrier rib  20 . 
         [0028]    A pair of supporting ribs  70 , which is included in the second housing space A 2 , includes a first supporting rib  71  and a second supporting rib  76 . The first supporting rib  71  extends toward the circuit substrate  46  from the dividing barrier rib  20 , and contacts the circuit substrate  46  and the dividing barrier rib  20 , such that the protection circuit module  40  is supported from the dividing barrier rib  20 . Further, the second supporting rib  76  extends toward the circuit substrate  46  from the auxiliary barrier rib  25 , and contacts the circuit substrate  46  and the auxiliary barrier rib  25 , such that the protection circuit module  40  is also supported from the auxiliary barrier rib  25 . The protection circuit module  40  may be stably housed within the second housing space A 2  by the first and second supporting ribs  71  and  76  having the above-described structure. The structures of the first and second supporting ribs  71  and  76  will be described in more detail as follows with reference to  FIGS. 3A and 3B . 
         [0029]    Turning now to  FIGS. 3A and 3B ,  FIG. 3A  is an exploded prospective view showing the first case  30 , the protection circuit module  40  and battery cells  5  illustrated in  FIG. 2  but prior to being combined, and  FIG. 3B  is a cross-sectional view taken by line I-F of  FIG. 3A . 
         [0030]    Referring to  FIGS. 3A and 3B , the first supporting rib  71  contacts the circuit substrate  46  and the dividing barrier rib  20 , such that the circuit substrate  46  is supported from the dividing barrier rib  20 . In the embodiments of the present invention, the first supporting rib  71  extends a first length L 1  from the dividing barrier rib  20 , where L 1  is equal to or greater than the thickness W 1  of the third driving circuit  43 . By having L 1  equal to or greater than a thickness W 1  of third driving circuit  43 , enough space is provided for third driving circuit  43  to fit between dividing barrier rib  20  and circuit substrate  46 . 
         [0031]    Further, the second supporting rib  76  contacts the circuit substrate  46  and the auxiliary barrier rib  25 , such that the circuit substrate  46  is supported from the auxiliary barrier rib  25 . In the embodiments of the present invention, the second supporting rib  76  extends a second length L 2  from auxiliary barrier rib  25 , where the second length L 2  is equal to or greater than the thickness W 2  of the first driving circuit  41 . By having second length L 2  equal to or greater than thickness W 2  of the first driving circuit  41 , the first driving circuit  41  can easily fit between the auxiliary barrier rib  25  and the circuit substrate  46 . 
         [0032]    Another design consideration of the embodiment of the present invention illustrated in  FIGS. 3A and 3B  pertains to the relationship between the heights of the supporting ribs  71  and  76  and the heights of the barrier ribs  20  and  25  respectively. In  FIGS. 3A and 3B , when the height of the dividing barrier rib  20  extending upward from the bottom portion  10  is defined as a first height H 1 , the height of the first supporting rib  71  from the bottom portion  10  in the first embodiment of the present invention is equal to first height H 1 . By having the first supporting rib  71  as tall as dividing barrier rib  20 , the process of inserting the protection circuit module  40  into the first case  30  is more foolproof and less prone to error as the barrier ribs  20  and  25  are less apt to interfere with the driving circuits  41 ,  42 ,  43  and  44 . The first bottom end P 1  of the circuit substrate  46  is inserted between the first and second supporting ribs  71  and  76  to couple the circuit substrate  46  to the first case  30 . This process is defined as the insertion process of the protection circuit module  40 . By having the supporting ribs  71  and  76  be sufficiently tall enough, workers may more easily perform the insertion process of the protection circuit module. This will be described in more detail as follows. 
         [0033]    Unlike the embodiment of the present invention, when the height of the first supporting rib  71  is lower than that of the dividing barrier rib  20 , the heights of the top ends of the first supporting rib  71  and the dividing barrier rib  20  are different from each other. Therefore, in early stage of the insertion process of the protection circuit module  40 , since the bottom end P 2  and a side P 3  of driving circuit  43  may contact with and jam into the dividing barrier rib  20  prior to contacting and being guided by rounded top edge R 1  of first supporting rib  71 , thereby frustrating the insertion process and possibly causing damage to the third driving circuit  43  or causing the third driving circuit to move or become separated from the circuit substrate  46 . 
         [0034]    However, in the structure of the first supporting ribs  71  according to the first embodiment of the present invention, when the workers perform the insertion process of the protection circuit module  40 , since the heights of the top ends of the first supporting rib  71  and the dividing barrier rib  20  are the same, the bottom end P 2  and the side P 3  of the third driving circuit  43  are guided by the rounded top edge R 1  of the first supporting rib  71  in early stage of the insertion process, such that the third driving circuit  43  may be safely and smoothly inserted into the proper position in first case  30 . That is, in the insertion process of the protection circuit module  40 , an occurrence of the third driving circuit  43  being interfered by the dividing barrier rib  20  is avoided, providing an easy and foolproof insertion process for workers assembling the battery pack. 
         [0035]    Furthermore, in the embodiments according to the present invention, when inserting the protection circuit module  40  into the first case  30 , the top ends of each of the first and second supporting ribs  71  and  76  may have guide portions R 1  and R 2  respectively having a round shape so that the first bottom end P 1  of the circuit substrate  46  can be easily inserted between the first and second supporting ribs  71  and  76 . Therefore, even when an assembly worker, during the insertion process, tries to insert the circuit substrate  46  at a location slightly deviated in the D 1  or −D 1  direction of  FIG. 3B  from the exact correct position, the top rounded edges R 1  and R 2  of first and second supporting ribs  71  and  76  can guide circuit substrate  46  smoothly to the correct location without having any of the driving circuits  41 ,  42 ,  43  or  44  contacting any of the barrier ribs  20  or  25 . 
         [0036]    Further, in the embodiments according to the present invention, the height of the second supporting rib  76  may have the same height H 2  as the auxiliary barrier rib  25 . Thus, like the effect realized by the structure of the first supporting rib  71  described above, the phenomenon that the first driving circuit  41  being interfered by the auxiliary barrier rib  25  during the insertion process is avoided, such that the workers may quickly and easily perform the insertion process of the protection circuit module  40 . 
         [0037]    Turning now to  FIG. 4 ,  FIG. 4  is a cross-sectional view of a battery pack  101  according to a second embodiment of the invention. In the description of the second embodiment of  FIG. 4 , with the exception of the first supporting rib, since the battery pack  101  shown in  FIG. 4  includes the same components as the battery pack  100  of  FIGS. 1 to 3B  of the first embodiment, like reference numerals are used to refer to like components and a duplicated description thereof will be omitted. 
         [0038]    Referring now to  FIG. 4 , the dividing barrier rib  20  has the first height H 1 , and the first supporting rib  72  has a second height H 3  that is higher than the first height H 1 . Therefore, upon performing the insertion process of the protection circuit module described previously with reference to  FIGS. 3A and 3B , the side P 3  of the third driving circuit  43  is guided to be inserted into the proper position by the first supporting rib  72 , and then the bottom end P 2  of the third driving circuit  43  is guided to be inserted into the proper position by the dividing barrier rib  20 . 
         [0039]    As a result, when the side P 3  of the third driving circuit  43  deviates from the exact position during the insertion process of the protection circuit module, a occurrence of the third driving circuit  43  being interfered by the dividing barrier rib  20  is prevented, thereby allowing for a smooth, foolproof and easily insertion process of the protection circuit module. 
         [0040]    By employing the structures of the battery packs according to the embodiments of the present invention, the supporting ribs are sufficiently high enough to guide the protection circuit module so that the protection circuit module can be assembled to the proper position without a driving circuit being interfered by the dividing barrier rib of the case. As a result, it is possible to provide a foolproof and easy operation assembling the protection circuit module into the case by workers in a fast-paced production environment. 
         [0041]    While the present invention has been described in connection with certain exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, and equivalents thereof.