Battery Pack PCB Mounting for Reliable Cell Connector Assembly
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Solution Overview
Problem
Existing battery packs face challenges in achieving a reliable and efficient electrical connection between battery cells and printed circuit boards, which can lead to complex assembly processes and potential faulty connections.
Innovation Solution
The battery pack design incorporates a mounting element in a cut-out of the printed circuit board to support the connection of the cell connector, utilizing a materially bonded connection process such as soldering or welding, and includes a cell-connector guide element to facilitate assembly, ensuring a robust and reliable electrical interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cell connector is directly connected to the printed circuit board without a mounting element, then the device complexity is reduced, but the reliability of the electrical connection deteriorates
Solution Approach 1:
The mounting element acts as an intermediary component between the cell connector and the printed circuit board. It provides a secure mechanical support structure within the cut-out of the PCB, enabling reliable electrical connection through material bonding (soldering or welding) while distributing mechanical stress away from the fragile electrical contacts.
2Strength
If the cell connector is rigidly fixed to the printed circuit board, then the mechanical strength of the connection is improved, but the strain relief capability deteriorates
Solution Approach 1:
The mounting element incorporates dynamic characteristics by allowing controlled movement and deformation. The strain relief element within the mounting structure can flex and deform under mechanical stress, absorbing shocks and preventing rigid stress transmission to the electrical contacts, thus maintaining both strength and reliability.
3Manufacturing precision
If a mounting element with cut-out is used to support the cell connector, then the interfacing quality is improved, but the manufacturing complexity increases
Solution Approach 1:
The mounting element is pre-formed with the cut-out structure and positioning features before assembly. The PCB is also pre-prepared with the cut-out opening, allowing the mounting element to be snap-fitted or mechanically secured in place before the final electrical bonding step, simplifying the overall manufacturing process while maintaining precision.
Data Source
AI summary
A battery pack is disclosed that includes a housing, including a cell holder, including at least one battery cell, the battery cell being at least partially received in the cell holder, including a cell connector, the cell connector being designed for electrical connection of the battery cell, and including a printed circuit board, the cell connector being electrically connected to the printed circuit board. The battery pack also has a mounting element to support the connection of the cell connector to the printed circuit board, the mounting element being located in a cut-out of the printed circuit board.