Battery Pack Connector Tab Design for Swelling

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Solution Overview

Problem

There is a demand for high-capacity, small-sized, lightweight secondary batteries that are resistant to swelling and overcharge/overdischarge, as existing solutions like increasing cell size are inefficient.

Innovation Solution

A battery pack design featuring at least two battery cells connected by a protection circuit module (PCM) assembly with connector tabs and cases to ensure secure coupling and prevent separation during swelling, using insulator tapes and adhesive tapes for stability and insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single PCM assembly controls multiple battery cells, then device complexity is reduced, but reliability may worsen due to potential contact issues during swelling

Engineering Contradiction:

Improvenumber of PCM assembliesVSAvoidcontact stability during swelling

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The connector tab is designed with flexibility to dynamically adapt to battery cell swelling. The tab can deform elastically when cells expand, maintaining continuous electrical contact without requiring rigid fixed structures, thus preserving reliability while using a single PCM assembly.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connector tab's physical parameters (shape, flexibility) are optimized to change in response to battery swelling. The tab's elastic properties allow it to accommodate volume changes of battery cells while maintaining stable electrical connection to the single PCM assembly.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If connector tabs are made flexible to accommodate swelling, then reliability improves, but manufacturing precision may worsen

Engineering Contradiction:

Improvecontact stability during swellingVSAvoidconnector tab positioning

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The connector tab design incorporates pre-calculated deformation margins and positioning tolerances that anticipate battery swelling. The manufacturing precision requirements are set with built-in cushions for variation, allowing the flexible tab to compensate for positioning deviations while maintaining reliable contact.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Quantity of substance

If multiple battery cells are connected in parallel, then capacity increases, but risk of overcharge and overdischarge increases

Engineering Contradiction:

Improvebattery capacityVSAvoidprotection against overcharge and overdischarge

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

Multiple battery cells are electrically connected in parallel through a single PCM assembly, merging their capacity while the PCM provides unified protection control. The single PCM manages charge/discharge protection for all connected cells simultaneously, achieving high capacity without proportionally increasing protection system complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8999536B2Battery pack

Publication Date: 2015.04.07 SAMSUNG SDI CO LTD

AI summary

A battery pack is disclosed. The battery pack includes at least two battery cells to provide a high capacity battery pack. The battery pack includes a single PCM assembly controlling at least two battery cells to decrease inferiority due to overcharge and overdischarge. Since a connector tab electrically connecting at least two battery cells to a single PCM assembly is provided, contacts are not separated during the swelling of the battery cells to prevent contact inferiority. A top case and a bottom case are provided to be coupled with at least two battery cells to maintain a secure coupling between the at least two battery cells.