Battery Pack Circuit Module Flatness via Lead Plate Support
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Solution Overview
Problem
In contemporary battery packs, the center of the protective circuit module is prone to bending downward due to external impacts during or after the manufacturing process.
Innovation Solution
A battery pack design that includes a bare cell with an electrode terminal, a circuit module positioned above the terminal, a positive temperature coefficient (PTC) unit between the cell and the module, and an electrode lead plate that contacts both the terminal and the PTC unit, with additional lead plates supporting the circuit module to prevent drooping. The electrode lead plate is welded to the terminal through a through hole in the circuit module, ensuring the module remains flat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the circuit module is disposed above the electrode terminal without additional support structures, then the device complexity is reduced, but the circuit module center bends downward due to external impacts
Solution Approach 1:
The patent introduces lead plates as intermediary support structures between the electrode terminal and the circuit module. These lead plates act as mediators that distribute external impacts and prevent the circuit module center from bending downward, while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent extends the support structure from a single-point connection to a distributed planar support using lead plates. By adding lateral extension in the horizontal dimension, the lead plates create a stable triangular support configuration that prevents downward bending without significantly increasing vertical complexity.
2Stability of the object's composition
If lead plates are added to support the circuit module, then the circuit module flatness is maintained, but the device complexity increases
Solution Approach 1:
The lead plates serve multiple functions simultaneously: they provide mechanical support to prevent circuit module bending, establish electrical connections between the electrode terminal and circuit module, and distribute external impacts. This multi-functionality reduces the need for separate components.
Solution Approach 2:
The patent merges the support function and electrical connection function into a single integrated lead plate structure. By combining these functions, the design avoids adding separate support brackets or mounts, thereby minimizing the increase in device complexity.
3Reliability
If the electrode lead plate is welded through the through hole, then the electrical connection is ensured, but the manufacturing precision requirement increases
Solution Approach 1:
The patent creates a localized welding zone through the through hole, concentrating the precision requirement to a specific small area rather than requiring precision across the entire assembly. The through hole acts as a localized guide that defines the welding position, reducing overall manufacturing precision demands.
Solution Approach 2:
The through hole serves as an intermediary feature that guides the electrode lead plate to the correct welding position on the electrode terminal. This predefined geometric feature acts as a locator, reducing the precision burden on the welding operation itself.
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 design effectively prevents the center of the protective circuit module from drooping due to external impacts during or after the manufacturing process, maintaining the module's flatness and ensuring proper functionality.
Implementation Method 1
a positive temperature coefficient (PTC) unit is respectively electrically connected to the bare cell and the protective circuit module in order to prevent a current from flowing when an internal temperature of the bare cell is increased
Implementation Method 2
the electrode lead plate is welded to the electrode terminal through the through hole
Data Source
AI summary
Provided is a battery pack. The battery pack may prevent a center of a protective circuit module from being bent by external impacts during or after a process of manufacturing a battery pack. The battery pack includes a bare cell from which an electrode terminal protrudes, a circuit module disposed above the electrode terminal, a positive temperature coefficient (PTC) unit disposed between the bare cell and the circuit module, the PTC unit being electrically connected to the bare cell and the circuit module, and an electrode lead plate having one side contacting the electrode terminal and the other side contacting the PTC unit, the electrode lead plate having a top surface contacting a bottom surface of the circuit module.