Low-Resistance Battery Pack Interconnect via PCB Aperture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rechargeable battery packs face increased electrical resistance due to tab connections, which hampers efficient charge and discharge performance and complicates manufacturing processes, failing to meet the growing power demands of portable electronic devices.
Innovation Solution
A battery pack design featuring a low-resistance interconnect between the printed circuit board (PCB) and the rechargeable cell, utilizing a conductive PCB interconnect aperture and a battery-pack interconnect that forms a secure direct electrical connection through mechanical friction or additional methods like soldering, welding, and conductive gluing, reducing material usage and enhancing contact intimacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tab connections are used to connect the battery to the PCB, then the manufacturing process is simplified, but the electrical resistance increases and charge/discharge efficiency decreases
Solution Approach 1:
The patent removes the tab component from the battery structure and replaces it with a direct interconnect between the electrode assembly and PCB. This extraction of the unnecessary tab element eliminates the additional resistance interface while simplifying the overall manufacturing process by reducing the number of components and assembly steps.
Solution Approach 2:
The patent merges the tab function directly into the interconnect structure that joins the electrode assembly to the PCB. By combining these functions into a single integrated interconnect component, the design eliminates the separate tab element and its associated resistance, while maintaining electrical connection functionality.
2Reliability
If tab connections are used in the battery design, then the electrical connection is established, but the device complexity increases and production rate decreases
Solution Approach 1:
The patent combines the electrical connection function into a single integrated interconnect structure that directly joins the electrode assembly to the PCB. This merging eliminates the separate tab component and reduces the number of connection interfaces, thereby reducing device complexity while maintaining reliable electrical connection through a streamlined design.
3Ease of manufacture
If tab connections are used, then the battery can be assembled, but the production efficiency decreases and manufacturing becomes more complex
Solution Approach 1:
The patent extracts and removes the tab component from the battery assembly process. By eliminating this unnecessary intermediate component, the manufacturing process is simplified and the number of assembly steps is reduced, thereby increasing production rate and efficiency while maintaining the ability to assemble the battery.
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
The solution results in improved charge and discharge characteristics with lower overall resistance, simplifying manufacturing processes and increasing production efficiency while supporting both electrical and structural integrity.
Implementation Method 1
The PCB-interconnect aperture has an inner surface that is electrically conductive and can be electrically coupled to at least one layer of the PCB. The internal conductive surface of the PCB-interconnect aperture can be coated with any suitable conductive material having suitable plating and conductivity characteristics
Implementation Method 2
This direct electrical connection between the PCB interconnect and the battery-pack interconnect can be formed by simple conductive connection that uses mechanical friction taking place between the outer surface of the battery-pack interconnect and inner surface of the PCB-interconnect aperture
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A battery pack comprising: at least one battery including at least one electrode and at least one terminal in electrical connection with the electrode; a printed circuit board (PCB) comprising at least one layer having an electrical circuit in electrical connection with the at least one battery, the PCB including at least one PCB interconnect for electrical connection with the at least one battery; and at least one battery-pack interconnect in electrical connection with the at least one PCB interconnect and the at least one terminal of the battery. The PCB interconnect comprises a PCB-interconnect aperture formed therein and having an electrically conductive inner surface structured to receive the battery-pack interconnect for direct electrical connection between the two.