Battery Pack Frame Ribs for Precise PCM Tab Welding
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Solution Overview
Problem
Existing battery packs face challenges in easily and securely electrically connecting protective circuit modules to battery cells, which complicates the welding process and requires additional jigs for precise positioning.
Innovation Solution
A battery pack design featuring a frame with pressing ribs that securely position and press the electrode tab and protective circuit module together, allowing for easy electrical connection and welding without the need for separate jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate welding jig is used to fix the positions of battery cells and protective circuit module, then positioning precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The frame integrates both the cell accommodation function and the positioning function for the protective circuit module into a single structure. The pressing ribs that originally served only to secure cells now also perform the positioning function, eliminating the need for a separate welding jig and reducing overall device complexity while maintaining positioning precision.
Solution Approach 2:
The frame is designed with multi-functionality: it accommodates battery cells, positions the protective circuit module, and provides pressing force for electrical connection. This universal structure replaces multiple separate components (frame, positioning jig, welding jig) with a single integrated component, solving the contradiction between precision and complexity.
2Ease of operation
If battery cells and protective circuit module are loosely positioned, then ease of assembly is improved, but electrical connection reliability deteriorates
Solution Approach 1:
The frame is pre-designed with pressing ribs at specific positions and heights that automatically provide the necessary pressing force when cells are installed. This preliminary structural arrangement ensures that proper contact pressure is achieved during normal assembly without requiring additional adjustment or tightening steps, maintaining both ease of assembly and connection reliability.
3Reliability
If pressing force is applied to secure the protective circuit module, then connection reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
Instead of requiring uniform high precision across the entire frame structure, the design applies localized pressing force only at specific points where the pressing ribs contact the protective circuit module and electrode tabs. This local quality approach concentrates the necessary pressure at critical connection points while allowing other areas of the frame to have standard manufacturing tolerances, thus maintaining connection reliability without excessively high overall precision requirements.
Data Source
AI summary
Provided is a battery pack. The battery pack includes: a battery cell; a protective circuit module electrically connected to an electrode tab extending from the battery cell; and a frame including a frame main body and a first pressing rib, wherein the frame main body forms a cell accommodation portion configured to accommodate the battery cell, and the first pressing rib protrudes from the frame main body in a direction opposite the cell accommodation portion to press the electrode tab and the protective circuit module in a direction in which the electrode tab and the protective circuit module face each other.According to the present disclosure, the battery pack has an improved structure for easily electrically connecting the battery cell and the protective circuit module to each other.