Battery Pack Connection Block for Reliable Tab Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery protection circuit modules face challenges in efficiently utilizing internal space and forming reliable electrical connections with electrode tabs, often resulting in thermal damage and defective products due to soldering methods.
Innovation Solution
A battery assembly that incorporates a connection block system, where electrode tabs are electrically coupled to a protection circuit module via connection blocks fixed to the substrate, allowing for easy welding operations and minimizing thermal damage, while optimizing internal space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering method is used to connect wires to hard PCB, then electrical connection is formed, but thermal damage occurs to circuit devices and manufacturing defects increase
Solution Approach 1:
The patent introduces a connection block as an intermediary component between the electrode tab and the protection circuit module. This connection block serves as a mediator that receives the electrode tab through a through-hole, allowing electrical connection to be formed without direct soldering to the protection circuit board, thereby avoiding thermal damage to sensitive circuit devices while maintaining reliable electrical connectivity
2Reliability
If connection blocks are added to connect electrode tabs and PCM, then electrical connection is improved, but inner space of PCM is reduced
Solution Approach 1:
The patent utilizes the vertical dimension by routing the electrode tab through a through-hole in the connection block, extending from one surface to the other. This three-dimensional arrangement allows the connection block to be integrated into the existing PCM structure without significantly increasing its footprint or reducing its inner space, as the connection is formed along the depth dimension rather than requiring additional lateral space
3Ease of manufacture
If welding operation is performed to connect electrode tab and PCM, then electrical connection is formed, but thermal damage may occur to substrate and protection circuits
Solution Approach 1:
The connection block acts as a thermal buffer and intermediary structure that isolates the welding operation from the sensitive protection circuit board. The electrode tab is welded to the connection block, which is mechanically and electrically connected to the PCM through a through-hole, thereby enabling easy welding operations while preventing heat from directly affecting the substrate and protection circuits
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
The connection block system facilitates reliable electrical connections, reduces thermal damage, and maximizes space within the battery pack, leading to improved manufacturing efficiency and reduced defects.
Implementation Method 1
a connection block to enable a welding operation for connecting an electrode tab and a protection circuit module (PCM) to be easily performed
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A battery assembly comprising: a battery cell; a protection circuit module; and a connection block; wherein the battery cell comprises an electrode tab; and the electrode tab is electrically coupled to the protection circuit module via the connection block.