Battery Pack LCPCB Alignment for Pouch Cell Assembly
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Solution Overview
Problem
Conventional battery packs for power tools and portable devices face inefficiencies in design and manufacturing, particularly in the integration and alignment of pouch-type battery cells, leading to suboptimal performance and assembly challenges.
Innovation Solution
A battery pack design featuring a lead collection printed circuit board (LCPCB) with specific slot configurations and a battery management system (BMS) that aligns and connects pouch-type battery cells efficiently, along with a state of charge printed circuit board (SOCPCB) for charge management, within a housing that facilitates easy assembly and optimal electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pouch-type battery cells are used in conventional battery packs, then the battery pack can be designed with flexible form factors, but alignment and connection difficulties arise during assembly
Solution Approach 1:
The LCPCB serves as an intermediary component between the pouch-type battery cells and the battery pack housing. It provides a standardized interface with slots that guide and align the battery cell tabs during assembly, eliminating alignment difficulties while maintaining the flexibility benefits of pouch cells
Solution Approach 2:
The LCPCB is pre-configured with slots at specific positions and orientations before assembly. This preliminary arrangement of connection points ensures that battery cells are automatically aligned correctly during insertion, solving the alignment problem before assembly occurs
2Quantity of substance
If multiple pouch-type battery cells are integrated into a single battery pack, then higher capacity is achieved, but connection and management complexity increases
Solution Approach 1:
The LCPCB performs multiple functions simultaneously: it provides electrical connections for multiple battery cells, manages charge distribution, monitors cell states, and provides mechanical support. This multi-functionality consolidates what would otherwise be separate complex subsystems into a single integrated component
Solution Approach 2:
The patent combines the lead collection function, charge management, and cell monitoring into a single LCPCB assembly. By merging these functions into one component rather than using separate systems, the overall complexity of managing multiple battery cells is reduced
Data Source
AI summary
The battery pack includes a battery pack housing operably connectable to a power tool, at least two pouch-type battery cells disposed in the battery pack housing, the at least two pouch-type battery cells including a first battery cell and a second battery cell, each of the at least two pouch-type battery cells having a first tab and a second tab, and battery pack terminals electrically connectable to power tool terminals of the power tool and electrically connected to the at least two pouch-type battery cells. A first battery pack power terminal of the battery pack terminals is aligned with a first tab of the first pouch-type battery cell and a first tab of the second pouch-type battery cell. A second battery pack power terminal of battery pack terminals is aligned with a second tab of the first pouch-type battery cell and a second tab of the second pouch-type battery cell.