Battery Pack PCM Tab Structure for Impact-Resistant Connections
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Solution Overview
Problem
Existing battery packs face challenges in maintaining reliability and mechanical strength, particularly in withstanding external impacts during repeated charging and discharging cycles.
Innovation Solution
A battery pack design featuring a terrace-supported protection circuit module (PCM) with a second connection tab that includes rotatable tab bodies connected by deformable bridges and a fixing tape with a separation region to enhance mechanical stability and prevent additional load on the connection tabs during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid connection structure is used between PCM and battery cell, then electrical connection reliability is improved, but mechanical strength under external impact deteriorates
Solution Approach 1:
The connection tab is designed with bridges that can elastically deform under external impact, allowing the structure to dynamically adapt to mechanical stress while maintaining electrical connection. The bridges bend to absorb impact energy, preventing permanent damage to the electrical connection between PCM and battery cell.
Solution Approach 2:
The bridge thickness is specifically optimized within the range of 0.05-0.15mm to achieve the right balance between rigidity for electrical connection and flexibility for impact absorption. This parameter optimization allows the connection structure to maintain reliability while withstanding mechanical impacts.
2Stability of the object's composition
If the bridge thickness is increased to improve rigidity, then structural stability is improved, but impact resistance deteriorates
Solution Approach 1:
The bridge thickness is precisely controlled within 0.05-0.15mm to achieve optimal balance between structural stability and impact resistance. This specific parameter range provides sufficient rigidity for maintaining structural integrity while allowing enough flexibility to absorb impact energy without breaking.
Solution Approach 2:
The bridges are designed to exhibit dynamic behavior under impact, bending elastically to absorb shock while maintaining structural stability during normal operation. This dynamic characteristic allows the structure to be stable during use but resilient under impact conditions.
3Stability of the object's composition
If fixing tape is applied over the entire connection tab area, then PCM fixation is improved, but additional load on connection tabs during impact increases
Solution Approach 1:
The fixing tape application area is segmented into two distinct zones: an adhesive region for PCM fixation and a separation region that avoids the connection tabs. This segmentation allows the PCM to be securely fixed while preventing the fixing tape from adding additional load to the already stress-prone connection tabs during impact.
Solution Approach 2:
The fixing tape has different functional properties in different regions: the adhesive region provides strong fixation for the PCM, while the separation region provides no adhesion to avoid loading the connection tabs. This local differentiation of quality optimizes both fixation and impact resistance.
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 ensures stable power supply and improved mechanical strength by securing sufficient rigidity for the connection structure, reducing damage from repeated external impacts and maintaining efficient power supply.
Implementation Method 1
a plurality of bridges configured to be bent and deformed in conjunction with a change in an angle between the first tab body and the second tab body
Implementation Method 2
a first connection tab extending from the terrace and electrically connected to the battery cell
Implementation Method 3
a second connection tab provided between the PCM and the first connection tab and configured to electrically connect the PCM to the battery cell
Data Source
AI summary
The present disclosure is directed to providing a battery pack with improved mechanical strength. The present disclosure provides a battery pack including a battery cell, a terrace extending from the battery cell, a protection circuit module (PCM) disposed to face the terrace, a first connection tab extending from the terrace and electrically connected to the battery cell, and a second connection tab provided between the PCM and the first connection tab and configured to electrically connect the PCM to the battery cell.