Battery Pack Connection Slot for Reliable Electrical Contact
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Solution Overview
Problem
The existing secondary battery pack manufacturing process is inefficient and costly due to the need for a separate connection member and the difficulty in welding small-sized connection members, leading to increased material costs and production time.
Innovation Solution
A secondary battery pack design that integrates a connection slot within the battery case, allowing terminal connection units to be directly inserted and electrically connected to the protection circuit module without a separate connection member, using a conductive metal plate with a unique structure for reliable electrical contact and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate connection member (clad) is used to connect the protection circuit module to the battery cell, then electrical connection is achieved, but material cost increases and welding becomes very difficult due to small size
Solution Approach 1:
The connection slot is integrated directly into the battery case structure, merging the connection member function with the battery case. This eliminates the need for separate small-sized connection members that are difficult to weld, while maintaining reliable electrical connection between the protection circuit module and battery cell through the integrated slot structure
Solution Approach 2:
The connection slot acts as an intermediary structure that facilitates electrical connection without requiring direct welding of small connection members. The slot provides a structured interface that enables easier manufacturing while ensuring reliable electrical contact between components
2Reliability
If welding is performed twice to connect the connection member to the battery cell and protection circuit module, then electrical connection is achieved, but production rate decreases and production cost increases
Solution Approach 1:
By integrating the connection slot into the battery case structure, the patent reduces the number of separate welding operations required. The integrated structure allows for simplified connection processes that maintain electrical reliability while improving production efficiency by eliminating redundant welding steps
3Reliability
If a separate connection member is used, then electrical connection between battery cell and protection circuit module is achieved, but material cost increases
Solution Approach 1:
The connection slot is merged with the battery case structure, eliminating the need for separate connection members. This integration reduces material costs by removing redundant components while maintaining the essential electrical connection function between the battery cell and protection circuit module
Solution Approach 2:
The battery case is designed to serve multiple functions: it provides structural containment and simultaneously serves as the connection interface through the integrated connection slot. This multi-functionality reduces the need for separate connection members, thereby reducing material costs while maintaining connection reliability
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
This design reduces material costs, eliminates the need for welding, ensures reliable electrical connections, and simplifies the manufacturing process by integrating the connection slot with the battery case, thereby improving process efficiency and preventing bonding failures.
Implementation Method 1
a connection slot formed at a top surface of the body plate so that a portion of the terminal connection unit is inserted and accommodated therein to be electrically connected to the electrode terminal
Data Source
AI summary
Disclosed is a secondary battery pack capable of improving process efficiency and reducing manufacture costs. The secondary battery pack includes a battery cell having an electrode terminal formed at a top end of a battery case; a protection circuit module having a battery cell connection terminal; and at least two terminal connection units having one end connected to the electrode terminal of the battery cell and the other end contacted and electrically connected to the battery cell connection terminal of the protection circuit module, wherein the battery case includes a battery can having an open top portion into which the electrode assembly is inserted, and a cap assembly coupled to the open top portion of the battery can, and wherein the cap assembly includes a body plate, and a connection slot is formed at a top surface of the body plate so that a portion of the terminal connection unit is inserted and accommodated therein to be electrically connected to the electrode terminal.