Battery Pack Lead Tab Latching for Solder-Free PCM Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs require complex soldering for connecting protective circuit modules to battery cells, which increases the risk of defects and makes repairs difficult.
Innovation Solution
A battery pack design that uses latching portions on second lead tabs to electrically connect with first lead tabs of the protective circuit module, eliminating the need for soldering by inserting the latching portion into a fastening hole, allowing for easy connection and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect protective circuit module to battery cells, then electrical connection is achieved, but manufacturing complexity and defect risk increase
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical mechanism) with a mechanical insertion mechanism. The latching portion is simply inserted into the fastening hole to establish electrical connection, eliminating the need for soldering equipment, temperature control, and flux materials. This mechanical substitution reduces manufacturing process complexity while maintaining connection reliability.
Solution Approach 2:
The patent introduces an intermediary structure - the latching portion and fastening hole interface - that mediates the connection between the protective circuit module and battery cells. This intermediary mechanical interface simplifies the connection process by providing a straightforward insertion mechanism rather than requiring direct soldering between components.
2Reliability
If soldering is used to connect protective circuit module to battery cells, then electrical connection is achieved, but repairability deteriorates
Solution Approach 1:
The patent segments the connection system into separable components with distinct connection interfaces (latching portion and fastening hole). This segmentation allows the protective circuit module to be easily separated from battery cells for repair or replacement, unlike soldered connections which require destructive desoldering processes.
Solution Approach 2:
By replacing soldering with a mechanical insertion system, the patent enables simple mechanical removal and reinstallation of components. The latching portion can be easily extracted from the fastening hole without specialized equipment, dramatically improving repairability while maintaining connection reliability during normal operation.
Data Source
Figure 1~2A
Figure 2B~3A
Figure 3B~3C
AI summary
A battery pack of the present disclosure includes: a holder case accommodating a plurality of battery cells, each of the battery cells including an electrode portion on each end thereof; a protective circuit module mounted on an outer side of the holder case; at least one first lead tab including a fixing portion and a fastening portion, the fixing portion extending from a region of the protective circuit module facing the holder case toward the holder case, the fastening portion being bent from the fixing portion in a direction parallel to the holder case and extending toward the electrode portion of the battery cell; and a second lead tab electrically connected to the electrode portion of the battery cell and placed at a position corresponding to the fastening portion of the first lead tab of the protective circuit module.