Battery Connection Tab With Elastic Insertion Leg
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Solution Overview
Problem
Existing secondary battery designs face challenges in maintaining a stable and reliable electrical connection between the protection circuit module and bare cells, which complicates the fabrication process and can lead to unreliable battery performance.
Innovation Solution
The design incorporates a connection tab with an insertion leg that is elastically deformed to establish a stable connection between the protection circuit module and bare cells, eliminating the need for welding and simplifying the assembly process, while using a clad material with nickel and copper for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding methods are used to connect the protection circuit module to bare cells, then electrical connection reliability is improved, but fabrication process complexity and manufacturing difficulty increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion system. The connection tab with insertion leg is simply inserted into the bare cell holder to establish electrical connection, eliminating the need for welding equipment, skilled welders, and complex process control while maintaining reliable electrical connection.
Solution Approach 2:
The connection tab serves as an intermediary component between the protection circuit module and the bare cells. It provides a dedicated mechanical and electrical interface that simplifies the connection process, allowing the PCM to be mounted and connected through simple insertion rather than requiring direct welding between dissimilar components.
2Stability of the object's composition
If complex connection methods are used to ensure stable electrical connection, then connection stability is improved, but device complexity increases
Solution Approach 1:
The connection system is segmented into distinct functional components: the bare cell holder with insertion groove, the connection tab with insertion leg, and the PCM mounting structure. This segmentation allows each component to be optimized independently and simplifies assembly, as components can be pre-assembled and tested separately before final integration.
Solution Approach 2:
The connection tab is designed with elastic deformation capability, allowing it to dynamically adapt to slight variations in assembly tolerances and maintain stable electrical contact. The insertion leg can elastically deform during insertion and maintains contact pressure through its elastic recovery, ensuring reliable connection without over-constraining the assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures a stable and reliable electrical connection between the protection circuit module and bare cells, simplifying the battery fabrication process and improving the overall performance and reliability of the secondary battery.
Implementation Method 1
The bending portion may be between the first and second bare cells and may be elastically deformed
Implementation Method 2
The connection tab may include a clad material. The clad material may be a composite of an elastic material and an electrically conductive material. The elastic material may include nickel and the electrically conductive material may include copper
Data Source
AI summary
A secondary battery including a first bare cell, a second bare cell disposed to face at least a portion of the first bare cell, and a protection circuit module including a circuit board having an electrical circuit device mounted thereon and at least one connection tab between the first and second bare cells, the connection tab electrically connecting the circuit board to the first and second bare cells.