Battery Module Testing via Segmented Connectors
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Solution Overview
Problem
Existing battery modules face challenges in stably and easily testing the performance of protective circuit modules, which is crucial for preventing overcharge and overcurrent issues that can lead to explosions or fires, due to the difficulty in accurately measuring and controlling voltage, current, and temperature after the protective circuit board is installed.
Innovation Solution
A battery module design that includes a protective circuit module electrically connected to rechargeable batteries, a circuit connector, and a battery connector with sensing lines and control communication lines, allowing for detachable connections and easy testing through separate connectors to a tester, ensuring stable and accurate measurement and control of battery performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protective circuit board is installed and enclosed by a molding layer, then the protective circuit module is protected and stabilized, but it becomes difficult to test the performance of the protective circuit module
Solution Approach 1:
The battery module is divided into distinct functional components: the protective circuit module enclosed by a molding layer, and separate first and second connectors that interface with it. This segmentation allows the protective circuit module to be protected while maintaining accessible connection points for testing through the connectors.
Solution Approach 2:
The first connector and second connector serve as intermediary elements that bridge the gap between the enclosed protective circuit module and external testing equipment. These connectors enable electrical connection and performance testing without requiring access to the internal circuit board, thus resolving the contradiction between protection and testability.
2Ease of operation
If separate first and second connectors are installed for testing protective circuit module and rechargeable batteries, then testing becomes easier and more stable, but device complexity increases
Solution Approach 1:
The testing interface is segmented into two distinct connectors: the first connector specifically for testing the protective circuit module, and the second connector for testing the rechargeable batteries. This segmentation simplifies the testing operation by providing dedicated interfaces for each component, making it easier to perform targeted tests while the modular design manages the overall complexity.
Solution Approach 2:
The first connector is designed with multi-functionality, serving both as a structural component to connect the protective circuit module and as a testing interface that provides electrical connection for performance evaluation. This universal design reduces the need for separate specialized testing equipment, thereby managing complexity while improving ease of operation.
Data Source
AI summary
A battery module may include a plurality of rechargeable batteries; a receiving member that inserts the rechargeable batteries; a protective circuit module that is fixed on the receiving member and that is electrically connected to the rechargeable batteries; a circuit connector that is connected to the protective circuit module and that has a plurality of terminals; and a battery connector that is electrically connected to the rechargeable batteries and that is coupled to the circuit connector.