Battery Pack Connection Structure for Selective Component Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing connection methods for secondary battery packs, which rely on soldering or welding, are complex, inefficient, and prone to errors, leading to safety issues and the need for costly and wasteful replacement of entire battery packs due to defects.
Innovation Solution
A connecting structure that uses a physical connection method, involving a metal plate with electrode and circuit connecting units, and a circuit terminal unit inserted into a connection hole in the PCB substrate of the protection circuit module, allowing for selective connection and separation without soldering or welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or welding is used to connect the core pack and protection circuit module, then electrical connection is achieved, but the production process becomes complex and expensive
Solution Approach 1:
The patent replaces the thermal/mechanical welding or soldering process with a pure mechanical connection system. The metal plate connects to the PCB substrate through a connection hole using only mechanical insertion and retention forces, eliminating the need for soldering irons, welding equipment, and associated thermal processes. This mechanical substitution simplifies the production process while maintaining reliable electrical connection.
Solution Approach 2:
The connection structure is divided into separate components: a metal plate with connection portion, a PCB substrate with connection hole, and a retention component. These segmented parts can be assembled independently and connected through simple mechanical insertion, replacing the integrated welding process. This segmentation allows for easier manufacturing, assembly, and disassembly.
2Reliability
If soldering or welding is used to connect the core pack and protection circuit module, then electrical connection is achieved, but short circuits may occur due to vibrations or external impacts
Solution Approach 1:
The retention component (such as a snap-fit, clip, or screw mechanism) is designed to preemptively secure the metal plate to the PCB substrate before any vibrations or external impacts occur. This beforehand cushioning ensures that the electrical connection is mechanically locked and protected against disconnection or short circuits caused by subsequent vibrations or impacts during battery operation.
3Reliability
If soldering or welding is used to connect the core pack and protection circuit module, then electrical connection is achieved, but the entire battery pack must be replaced due to defects
Solution Approach 1:
The connection structure uses segmented, modular components (metal plate, PCB substrate, retention component) that can be independently removed and replaced. If a defect is found in one component, only that specific component needs to be replaced rather than the entire battery pack, significantly reducing repair costs and improving ease of maintenance.
Solution Approach 2:
The mechanical connection allows for dynamic assembly and disassembly of the connection components. The retention component can be easily engaged or disengaged, enabling quick replacement of defective parts without requiring complex disassembly of the entire battery pack, thus improving repairability and reducing maintenance costs.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed is a connecting structure for a secondary battery and a secondary battery pack including the same. The connecting structure for a secondary battery electrically connects a core pack where two or more unit cells are electrically connected and a protection circuit module made of the unit cells of the core pack and a PCB substrate. The connecting structure includes a metal plate having an electrode connecting unit connected to an electrode of each unit cell of the core pack and a circuit connecting unit connected to the protection circuit module, and a circuit terminal unit electrically connected to the circuit connecting unit by being located in a connection hole formed in the PCB substrate of the protection circuit module so that the upper and lower portions of the PCB substrate communicate with each other, wherein the circuit connecting unit is electrically connected to the circuit terminal unit by means of a physical connection method which allows selective connection and separation.