Battery Pack Patterned PCBs Eliminate Monitoring Wires
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Solution Overview
Problem
Existing battery packs face issues with manufacturing complexity and reliability due to interference between the case and monitoring wires, leading to potential short circuits and coating stripping, which complicates the manufacturing process and reduces stability.
Innovation Solution
The design incorporates patterned printed circuit boards (PCBs) with connecting tabs that eliminate the need for monitoring wires, simplifying the manufacturing process and preventing short circuits by electrically connecting battery cells directly to a battery management system through soldering portions, thereby enhancing stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If monitoring wires are used to connect battery cells to the battery management system, then electrical connection is achieved, but interference between wires and the case causes short circuits and coating stripping
Solution Approach 1:
The patent extracts and eliminates the monitoring wires from the battery pack structure, replacing them with printed circuit boards that provide electrical connections through pattern portions and tabs. This removal of the problematic wires directly resolves the interference and short circuit issues while maintaining the necessary electrical connectivity between battery cells and the management system
Solution Approach 2:
The patent replaces the mechanical wire-based connection system with a printed circuit board system that uses pattern portions and tabs for electrical connections. This substitution eliminates the flexibility and interference characteristics of wires while providing a more stable and integrated connection structure that prevents short circuits and coating damage
2Reliability
If monitoring wires are used for connecting battery cells, then electrical connectivity is established, but the manufacturing process becomes complex and less efficient
Solution Approach 1:
The patent merges the electrical connection function previously performed by separate monitoring wires into an integrated printed circuit board structure. The PCBs with pattern portions and tabs combine multiple connection functions into a single component, simplifying the manufacturing process and improving production efficiency while maintaining reliable electrical connectivity
Solution Approach 2:
The patent replaces the wire-based mechanical connection system with a printed circuit board system that enables more efficient manufacturing. The PCB structure allows for standardized assembly processes and eliminates the complex wire routing and connection steps, thereby improving productivity without compromising electrical connectivity
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
This solution simplifies the manufacturing process, improves working efficiency, and prevents short circuits, resulting in a more stable and reliable battery pack with reduced risk of interference.
Implementation Method 1
The first ends of the pattern portions and corresponding ones of the tabs are electrically connected by the soldering portions, respectively
Data Source
AI summary
A battery pack has a case which includes accommodating areas for battery cells located between and printed circuit boards (PCBs). Each PCB has openings that correspond to respective accommodating areas. The battery pack also has tabs connected to the battery cells through the openings in the PCBs. First ends of pattern portions of a first PCB are connected to respective tabs of the first PCB, and second ends of the pattern portions are at a first pattern collecting portion in the case. First ends of pattern portions of a second PCB are connected to respective tabs corresponding to the second PCB, and second ends of the pattern portions of the second PCB are at a second pattern collecting portion in the case. A battery management system is connected to the batteries through the first and second PCBs.