Rechargeable Battery Pack Connection Member Design

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Solution Overview

Problem

The existing methods for connecting a protection circuit module to a connection tab in rechargeable battery packs require skilled techniques, involve hazardous processes like welding or soldering, and can lead to electrical shorts, damage to circuit components, and design constraints due to solder dispersion, while also posing risks of fire or explosion.

Innovation Solution

A rechargeable battery pack design featuring a connection member with a body portion, guide portion, and supporting portion, integrally formed by cutting and bending a conductive plate, which is inserted into a through hole on the printed circuit board to establish electrical contact without welding or soldering, thereby simplifying the connection process and eliminating the need for soldering facilities and materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding or soldering is used to connect the connection tab to the protection circuit board, then electrical connection is established, but the process requires highly skilled techniques, increases manufacturing complexity, and creates safety hazards

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconnection process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the thermal/mechanical welding or soldering process with a pure mechanical insertion system. The connection tab is simply inserted into the through hole of the protection circuit board to establish electrical connection, eliminating the need for complex welding equipment, skilled operators, and thermal management systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connection structure is divided into separate components: the connection tab, the protection circuit board with through hole, and the case. This segmentation allows each component to be manufactured independently and connected through simple insertion, reducing overall manufacturing complexity while maintaining reliable electrical connection.

Inventive Principle:

Principle #1Segmentation

2Reliability

If welding or soldering is used to connect the connection tab to the protection circuit board, then electrical connection is established, but temperature increase may damage integrated circuits and circuit parts

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidprocessing temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent eliminates thermal processes by replacing welding/soldering with mechanical insertion. The connection tab is connected to the protection circuit board through simple insertion into a through hole, completely avoiding temperature increase and thermal damage to sensitive electronic components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If soldering is used to connect the connection tab to the protection circuit board, then electrical connection is established, but solder dispersion affects design freedom of the circuit board

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidcircuit board design freedom

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The connection structure separates the electrical connection function from the circuit board design. The through hole provides a standardized insertion point that does not constrain the overall circuit board layout, allowing greater design freedom compared to soldering which requires precise land patterns and pad designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Replacing soldering with mechanical insertion eliminates the need for solder lands, pad designs, and flux application areas, thereby increasing the flexible space available for circuit board layout and component placement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If welding or soldering facilities and materials are used, then electrical connection is established, but manufacturing costs increase and processing time increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces complex thermal processing equipment and materials (welding machines, soldering irons, flux, solder wire) with simple mechanical insertion tools. This dramatically reduces equipment investment, material costs, and processing time while maintaining reliable electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Reliability

If welding or soldering is used to connect the connection tab to the protection circuit board, then electrical connection is established, but fire or explosion may occur due to electrical short during connection process

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidsafety hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates thermal processes that could cause fire or explosion by using mechanical insertion. The connection tab is connected through simple insertion into a through hole without generating heat, sparks, or using flammable materials like flux, thereby completely eliminating fire and explosion hazards during the connection process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potential harm of thermal processes by completely eliminating them. Instead of trying to manage thermal risks, the design uses a cold mechanical connection method that inherently prevents fire and explosion hazards while maintaining electrical connection reliability.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS8927132B2Rechargeable battery pack

Publication Date: 2015.01.06 SAMSUNG SDI CO LTD

AI summary

A rechargeable battery pack including: a cell pack including at least one unit cell; a protection circuit module including a printed circuit board including a protection circuit of the cell pack; a connection member inserted in a through hole of the printed circuit board and electrically connected to the printed circuit board; and a connection tab electrically connected to the cell pack inserted into and electrically connected to the connection member.