Battery Module Plug-Socket Assembly Without Welding Pads
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Solution Overview
Problem
The existing battery module manufacturing process requires welding to connect protection circuit modules and battery management units, leading to potential defects, increased costs, and larger module sizes due to welding pads, as well as the need for separate welding equipment and complex condition management.
Innovation Solution
A battery module design that integrates a protection circuit module with a thermal cut-out element and connects to a battery management unit using a detachable plug and socket system, eliminating the need for welding and allowing for easier assembly and replacement of defective cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect protection circuit module and battery management unit, then electrical connection is achieved, but manufacturing complexity and cost increase due to welding defects, equipment requirements, and condition management
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical connection system consisting of connection terminals and connection holes. This substitution eliminates the need for welding equipment and complex welding condition management while maintaining reliable electrical connection between the protection circuit module and battery management unit.
Solution Approach 2:
The patent divides the connection interface into separate components: connection terminals on one component and corresponding connection holes on the other component. This segmentation allows for simpler manufacturing of individual parts and easier assembly, replacing the integrated welding process with modular mechanical connection elements.
2Reliability
If welding pads are provided for welding process, then electrical connection is established, but battery module size increases due to occupied space by welding pads
Solution Approach 1:
The patent replaces welding pads (which occupy significant surface area) with mechanical connection terminals and holes that require minimal space. This substitution reduces the area occupied by connection interfaces while maintaining reliable electrical connection functionality.
3Reliability
If welding is used to connect battery cell to battery management unit, then electrical connection is achieved, but part loss occurs and manufacturing cost increases when welding defect occurs
Solution Approach 1:
The patent segments the connection system into separate, replaceable components (connection terminals and connection holes). If a defect occurs, only the defective terminal or hole needs to be replaced rather than discarding the entire battery module, thereby reducing part loss and manufacturing cost.
Solution Approach 2:
The connection terminals and holes are designed as simple, inexpensive components that can be easily replaced if defective. This approach is more economical than welding, where any defect requires disposal of the entire assembled unit.
4Reliability
If separate welding equipment is used for welding between battery cell and battery management unit, then welding connection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces the need for specialized welding equipment with simple mechanical connection components (terminals and holes) that can be assembled using basic assembly tools. This substitution dramatically reduces equipment complexity and manufacturing cost while achieving reliable electrical connection.
Data Source
AI summary
Disclosed is a battery module including a battery cell, a protection circuit module coupled integrally to the battery cell, the protection circuit module having a thermal cut-out element formed integrally therewith, a battery management unit connected to the protection circuit module, and a connection unit to detachably connect the protection circuit module and the battery management unit to each other.