Battery Pack SMT Busbar Connection for Compact Heat Dissipation

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Solution Overview

Problem

Conventional battery packs face inefficiencies in connecting battery cells to circuit boards due to low efficiency welding methods, high material consumption, and increased size, which also lead to heat concentration issues.

Innovation Solution

The battery pack employs a novel connection method using a metal plate on the circuit board, connected via surface mounting technology and laser welding, with a hot block for enhanced heat dissipation, reducing product volume and production costs while improving heat management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If welding method is used to connect busbar to circuit board, then electrical connection is achieved, but production efficiency is low and operating space requirement is high

Engineering Contradiction:

Improveproduction efficiencyVSAvoidoperating space requirement

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces the traditional welding process with a mechanical pressing connection system. A pressing device applies force through a pressing plate to mechanically connect the busbar with the circuit board, eliminating the need for welding operations. This substitution dramatically improves production efficiency and reduces operating space requirements while achieving reliable electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If welding method is used to connect busbar to circuit board, then electrical connection is achieved, but tin material consumption is high

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidtin material consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent eliminates the welding process entirely by using a mechanical pressing connection system. The pressing device applies controlled force to create direct mechanical and electrical contact between the busbar and circuit board without requiring any tin material, thereby reducing material consumption to zero while maintaining connection reliability through optimized pressing force and contact area.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If welding method is used to connect busbar to circuit board, then electrical connection is achieved, but battery pack size increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidbattery pack size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The mechanical pressing connection system requires minimal space compared to welding equipment and associated fixtures. The pressing plate and connection structure are compact, allowing the battery pack components to be closely arranged, thereby reducing the overall battery pack size while ensuring reliable electrical connection through optimized mechanical contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If conventional connection method is used, then electrical connection is achieved, but heat dissipation is insufficient

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidheat concentration

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent extracts the heat dissipation function from the connection structure by introducing a dedicated heat dissipation component. This separate component is thermally coupled to the connection area to conduct heat away from the busbar and circuit board interface, effectively managing heat concentration while preserving the reliability of the electrical connection.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This solution enhances the electrical connection reliability, reduces material consumption, and provides effective heat dissipation, resulting in a more compact, efficient, and cost-effective battery pack design.

Implementation Method 1

said metal plate is fixed to said circuit board using surface mounting technology

Methodology Applied

Scientific EffectSurface mounting technology: Soldering

Implementation Method 2

said lead board is laser welded to said metal plate

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 3

said hot block, which is in thermal contact with said metal plate to absorb heat from said lead board and said metal plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

a thermal conductive material is arranged between said hot block and said metal plate. Said thermal conductive material can be thermal conductive silicone or thermal conductive silicone pad

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20240162574A1A battery pack and an electric tool including the battery pack

Publication Date: 2024.05.16 TECHTRONIC CORDLESS GP

AI summary

The present invention discloses a battery pack and an electric tool that comprises such a battery pack. A battery pack comprises: one or a plurality of battery cells, a circuit board, which is located inside the housing of the battery pack, a lead board, which is connected to the electrode terminals of one or the plurality of battery cells, and a metal plate, which is arranged on said circuit board and electrically connects said lead board to the circuit in said circuit board, wherein said metal plate is fixed to said circuit board using the surface mounting technology.