Secondary Battery Pack With Depression Space And Protrusion Terminal
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Solution Overview
Problem
Existing secondary battery packs face challenges in achieving compact structure and efficient assembly due to the need for multiple welding or soldering processes for connecting protection circuit modules (PCMs) and positive temperature coefficient (PTC) elements, which increases manufacturing costs and reduces spatial efficiency.
Innovation Solution
A secondary battery pack design featuring a top cap with a depression space to house elements like the PCM and PTC elements, utilizing protrusion-type electrode terminals and through-holes for secure mechanical coupling without welding, simplifying the assembly process and enhancing structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple welding or soldering processes are used to connect PCMs and PTC elements, then reliable electrical connection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the welding/soldering process with a mechanical insertion system. The protrusion-type electrode terminal is simply inserted through the through-hole of the insulative mounting member to establish both mechanical and electrical connection, eliminating the need for complex thermal joining processes while maintaining reliable electrical connectivity.
2Reliability
If multiple welding or soldering processes are used to connect PCMs and PTC elements, then reliable electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive welding/soldering operations with a simple mechanical insertion process. The protrusion-type electrode terminal is directly inserted through the through-hole, eliminating the need for specialized welding equipment, consumables, and skilled labor, thereby significantly reducing manufacturing costs while maintaining connection reliability.
3Volume of moving object
If a compact battery pack structure is designed, then spatial efficiency is improved, but assembly difficulty increases
Solution Approach 1:
The patent divides the battery pack into modular components: the insulative mounting member with through-holes, the protrusion-type electrode terminal, and the PCM assembly. This segmentation allows each component to be independently manufactured and then easily assembled through simple insertion, maintaining compact overall dimensions while simplifying the assembly process.
Solution Approach 2:
The insulative mounting member acts as an intermediary component that facilitates easy assembly. Its through-hole design provides a guided path for the protrusion-type electrode terminal, enabling precise positioning and secure mechanical coupling without requiring complex alignment procedures, thus simplifying assembly in the compact structure.
4Ease of manufacture
If mechanical coupling without welding is used, then manufacturing cost is reduced, but connection strength may be compromised
Solution Approach 1:
The patent merges multiple functions into the single protrusion-type electrode terminal: it serves as both the electrical conductor and the mechanical fastener. The insertion of this terminal through the through-hole simultaneously establishes electrical connection and provides mechanical coupling through friction and geometric interference, achieving both electrical and structural integrity without welding.
Solution Approach 2:
The protrusion-type electrode terminal features a geometric shape with a head portion and a shaft portion that creates a mechanical interference fit when inserted through the through-hole. This curved/geometric design provides frictional engagement and prevents pull-out, ensuring strong mechanical connection without requiring thermal joining processes.
Data Source
AI summary
Disclosed herein is a secondary battery pack including a battery cell having an electrode assembly mounted in a battery case together with an electrolyte, a protection circuit module (PCM) having a protection circuit for controlling overcharge, overdischarge, and overcurrent of the battery cell, an insulative mounting member mounted to a top cap of the battery cell, and an insulative cap coupled to the upper end of the battery cell, wherein the top cap is provided with at least one protrusion-type electrode terminal, and the top cap is provided at a partial region where the protrusion-type electrode terminal is not formed with a space (depression space) depressed downward by a predetermined depth. The insulative mounting member is provided with a through-hole (a first through-hole) corresponding to the protrusion-type electrode terminal and a through-hole (a second through-hole) corresponding to the depression space, the PCM is provided with a coupling through-hole corresponding to the first through-hole, and the coupling of the insulative mounting member and the PCM to the battery cell is achieved by successively fixedly inserting the protrusion-type electrode terminal through the first through-hole of the insulative mounting member and the coupling through-hole of the PCM.