Battery Pack Tapping Screw for Low Resistance Connection
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Solution Overview
Problem
The existing battery packs face inefficiencies in charging and discharging due to high electrical resistance between the bare cell and the protection circuit substrate, which can increase during external impacts, affecting the stability and reliability of the battery pack.
Innovation Solution
A battery pack design that includes a cap plate with screw receiving grooves, a cover case with mounting grooves, and tapping screws that penetrate through holes and coupling holes, forming a secure and conductive connection between the cap plate and the protection circuit substrate, reducing contact resistance and enhancing stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bare cell and protection circuit substrate are connected using existing mounting methods, then the battery pack can be assembled, but the electrical resistance between the bare cell and protection circuit substrate becomes high, reducing charging/discharging efficiency
Solution Approach 1:
The patent combines the mechanical fastening function and electrical conduction function into a single integrated solution. The tapping screw serves dual purposes: mechanically securing the cap plate to the cover case while simultaneously providing a low-resistance electrical pathway between the protection circuit substrate and bare cell, eliminating the need for separate fasteners and conductive elements.
Solution Approach 2:
The tapping screw is designed as a multi-functional component that performs both mechanical fastening and electrical conduction. This universal component addresses multiple requirements (structural integrity and electrical connectivity) simultaneously, reducing overall system complexity and improving charging/discharging efficiency by eliminating high-resistance contact points.
2Reliability
If the battery pack is subjected to external impacts, then the battery pack must withstand the impact, but the electrical resistance between the bare cell and protection circuit substrate increases due to contact resistance
Solution Approach 1:
The patent integrates the mechanical fastening function and electrical conduction function into a single tapping screw assembly. This integration ensures that the electrical connection is mechanically robust and maintains stable contact under external impacts, preventing increases in contact resistance that would occur with separate fastening and conduction components.
Solution Approach 2:
The tapping screw body features a curved surface that complements the protruding unit's geometry, creating a conformal contact interface. This curved geometry distributes contact pressure more evenly and maintains reliable electrical contact under impact conditions, preventing contact resistance increases that would occur with flat or point-contact interfaces.
3Stability of the object's composition
If a secure connection is formed between the cap plate and cover case, then the battery pack stability improves, but the device complexity increases due to additional components like tapping screws and mounting grooves
Solution Approach 1:
The patent merges the fastening component (tapping screw) with the conduction path into a single integrated element. This reduces the total component count while maintaining secure mechanical and electrical connections, as the tapping screw simultaneously provides both structural fastening and electrical connectivity between the cap plate, cover case, and protection circuit substrate.
Solution Approach 2:
The tapping screw serves multiple functions: mechanical fastening of the cap plate to the cover case, providing an electrical conduction path, and maintaining contact pressure under impact. This multi-functionality reduces the number of separate components needed while achieving stable connections, as each component is designed to fulfill multiple roles in the assembly.
Data Source
AI summary
Provided is a battery pack formed by coupling a cover case and a bare cell. The battery pack includes: a bare cell including a cap plate having a surface in which at least one screw receiving groove is formed; a cover case disposed at a side of the cap plate, and having a surface in which at least one mounting groove is formed and a hole penetrating a center of the mounting groove; and at least one tapping screw including a head part and a body part that are mounted in the mounting groove of the cover case, wherein the body part penetrates the hole and is coupled to the screw receiving groove of the cap plate; wherein the cap plate includes a protruding unit formed in the second surface of the cap plate in correspondence to the screw receiving groove of the cap plate.