Battery Pack Ground-First Assembly to Prevent Circuit Damage
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Solution Overview
Problem
The assembly of power supply devices with secondary battery cells connected in series and parallel is prone to unintended damage due to unstable ground connections, leading to potential circuit destruction and malfunction, especially when the order of connection is not carefully managed.
Innovation Solution
The method involves connecting the battery-side ground terminal to the board-side ground terminal first, using a flexible member if necessary, to stabilize the ground connection and prevent premature contact between intermediate terminals, thereby ensuring a reliable and efficient assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead plates are used to connect battery holder and circuit board, then electrical connection is achieved, but unintended voltage application may occur during assembly causing circuit damage
Solution Approach 1:
The ground connection is established before connecting the circuit board to the battery holder. The ground terminal is preliminarily connected to the ground electrode terminal in advance, ensuring that the circuit board is already grounded before any other electrical connections are made, thereby preventing unintended voltage application during assembly
Solution Approach 2:
The ground connection is established in advance to counteract the potential harmful effect of unintended voltage application. By connecting the ground terminal to the ground electrode terminal before other connections, the circuit is protected from voltage spikes and rush currents that could occur if intermediate terminals were connected first
2Ease of manufacture
If circuit board is placed on battery holder with multiple lead plates, then electrical connections are established, but uncertainty exists about which connection contacts first
Solution Approach 1:
The ground connection is extracted and separated from the other electrical connections. The ground terminal is connected to the ground electrode terminal independently before the circuit board is placed on the battery holder, removing the uncertainty of connection order by handling the ground connection as a distinct preliminary step
Solution Approach 2:
The ground terminal connection is performed as a preliminary action before placing the circuit board on the battery holder. This ensures that the ground connection is established in advance, eliminating the uncertainty about which connection contacts first when multiple lead plates are used
3Reliability
If ground terminal is drawn outside from battery holder, then ground connection stability is improved, but handling difficulty increases
Solution Approach 1:
A flexible member is introduced as an intermediary between the ground terminal and the battery holder. This flexible member allows the ground terminal to be drawn outside from the battery holder while maintaining electrical connection, improving ground connection stability without significantly compromising handling ease
Data Source
AI summary
Unintentional damage of a power supply device during assembling of the device is avoided to increase workability of the assembling. The power supply device includes secondary battery cells each including an electrode terminal, a battery holder holding the cells, and a circuit board including a control circuit mounted thereon and electrically connected to the cells to control charging and discharging. A method of manufacturing the device includes connecting, to a board-side ground terminal disposed on the board, a battery-side ground terminal drawn outside from the holder as a ground of a total output of the cells electrically connected in series and/or parallel, mounting the board on a surface of the holder, and connecting, to respective one or more board-side intermediate terminals disposed on the board, one or more battery-side intermediate terminals disposed on the holder being electrically connected to at least one of the cells.