Battery Pack Electrode Tab Connection Structure Preventing Short Circuits
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Solution Overview
Problem
Existing battery packs face challenges in preventing short circuits between battery cells and protective circuit modules due to inadequate electrical connection structures, which can lead to operational failures and safety issues.
Innovation Solution
The battery pack incorporates a unique connection structure between the electrode tab and the protective circuit module, featuring a connection slot that creates a gap between the electrode tab and the module's surface, with a bent connection tab and support portions to ensure electrical isolation and prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode tab is directly connected to the protective circuit module surface, then electrical connection is simplified, but short circuit risk increases
Solution Approach 1:
A connection tab serves as an intermediary component between the electrode tab and the protective circuit module. The connection tab includes a first connection portion that contacts the electrode tab and a second connection portion that contacts the protective circuit module, thereby preventing direct contact between the electrode tab and the module surface while maintaining electrical connection. This mediator structure eliminates short circuit risk without significantly complicating the overall connection system.
Solution Approach 2:
The connection structure transitions from a two-dimensional surface contact to a three-dimensional spatial arrangement. The connection tab extends vertically from the protective circuit module surface, creating a gap that prevents short circuits while maintaining electrical connectivity. This dimensional change allows the electrode tab to connect to the module without touching the module surface, resolving the contradiction between simplicity and safety.
2Reliability
If a connection slot is introduced to create gap separation, then electrical isolation is improved, but manufacturing complexity increases
Solution Approach 1:
The protective circuit module surface is segmented by introducing a connection slot that separates the area where the electrode tab would otherwise contact the module. This slot creates distinct zones: one for electrical connection and another for isolation, preventing short circuits while being manufacturable through standard PCB fabrication processes.
3Reliability
If the connection tab is bent in the depth direction of the connection slot, then electrical connection stability is improved, but structural complexity increases
Solution Approach 1:
The connection tab is bent in the depth direction of the connection slot, creating a curved or angled structure instead of a straight one. This curvature allows the connection tab to nestle more securely into the connection slot, improving electrical connection stability and preventing loosening during operation. The bent structure maintains simplicity while enhancing reliability through geometric design.
Data Source
AI summary
A battery pack includes a battery cell having an electrode tab and a protective circuit module electrically connected to the electrode tab. The protective circuit module has a first surface in an assembling direction of the electrode tab and a second surface opposite the first surface. The electrode tab is separated from the first surface. Therefore, the battery pack has an improved connection structure between the battery cell and the protective circuit module, and short circuits can be prevented or substantially prevented.