Battery Pack Single Protection Circuit Board Module Integration
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Solution Overview
Problem
Existing battery packs face limitations in flexibility and assembly productivity due to the need for multiple protection circuit boards for each series and parallel connection of unit cells, leading to increased complexity and reduced volume energy density, especially as the number of unit cells increases.
Innovation Solution
A battery pack design that uses a single protection circuit board to manage multiple battery modules, allowing for flexible series and parallel connections without individual protection circuit boards for each unit cell, utilizing chip fuses and voltage detection lines to monitor cell states and prevent overcharge, over-discharge, and short-circuiting, while using lithium manganese composite oxide for safer and more compact positive electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple protection circuit boards are used for each series and parallel connection of unit cells, then battery safety and protection function are improved, but device complexity and assembly complexity increase significantly
Solution Approach 1:
The patent combines multiple protection circuit boards into a single integrated protection circuit board that manages multiple battery modules. This single board integrates the protection functions for all series and parallel connections, eliminating the need for separate protection boards for each connection point, thereby reducing assembly complexity while maintaining comprehensive protection.
Solution Approach 2:
The protection circuit board is designed with multi-functional capabilities to handle protection tasks for multiple battery modules simultaneously. It incorporates universal protection functions including overcharge protection, over-discharge protection, short-circuit protection, and temperature protection that can monitor and control multiple series-parallel connected modules through a single integrated system.
2Reliability
If multiple protection circuit boards are installed for each connection, then protection coverage is improved, but volume energy density decreases due to increased space occupation
Solution Approach 1:
By merging multiple protection circuit boards into one integrated board, the total volume occupied by protection circuits is significantly reduced. This single board design eliminates redundant circuitry and mounting spaces, thereby increasing the proportion of active battery material in the overall battery pack volume and improving volume energy density.
Solution Approach 2:
The universal protection circuit board provides comprehensive protection coverage for multiple battery modules through integrated monitoring and control functions. This multi-functional design ensures that protection coverage is maintained across all series and parallel connections without requiring additional physical space for multiple separate protection boards.
3Power
If unit cells are connected in series and parallel to increase electric capacity, then power output is improved, but production and maintenance complexity increases
Solution Approach 1:
The protection circuit board incorporates universal connection interfaces and standardized monitoring circuits that can accommodate various series and parallel configurations of battery modules. This multi-functional design allows the same protection board to manage different electric capacity requirements without requiring custom design modifications, thereby simplifying production for different power output levels.
Solution Approach 2:
The battery system is segmented into modular battery modules that can be flexibly connected in series and parallel configurations. The single protection circuit board is designed to monitor and control these modular segments individually while providing unified protection, making production and maintenance more manageable through standardized modular units.
4Productivity
If a single protection circuit board manages multiple battery modules, then assembly productivity is improved, but voltage and current resistance requirements for semiconductor elements increase
Solution Approach 1:
The protection circuit board employs a segmented monitoring approach where individual monitoring circuits track the voltage and current status of each battery module separately. This segmentation allows the use of lower-voltage-rated semiconductor elements for each individual module monitoring, while the integrated board provides unified protection across all modules, thus maintaining reliability without requiring high-voltage-rated components throughout.
Data Source
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AI summary
A battery pack includes a plurality of battery modules that house a plurality of unit cells in a case; and a protection circuit board that controls the charge and discharge of a plurality of the battery modules at once. The battery pack is highly flexible in series and parallel connection, high in assembly productivity and excellent in energy density.