Battery Pack Terminal Design for Compact Protective Circuit Modules
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Solution Overview
Problem
The challenge is to develop a battery pack that is both small in size and light in weight while maintaining stability, as the use of reactive materials like lithium limits the miniaturization and weight reduction due to safety concerns.
Innovation Solution
The battery pack design includes a protective circuit module with a novel terminal structure that optimizes space usage, featuring support portions, body portions, and extending portions to reduce the terminal's size and improve mounting efficiency, allowing for increased component space within the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the battery pack size and weight are reduced, then portability is improved, but safety is compromised due to the use of reactive materials like lithium
Solution Approach 1:
The battery pack is divided into modular components: multiple battery cells arranged in a specific configuration, a protective circuit module with integrated terminals, and a housing that segments the internal space. This segmentation allows for optimized space utilization while maintaining safety through structured organization of reactive materials
Solution Approach 2:
The terminal structure is nested within the protective circuit module, with the terminal support portion integrated into the module body. The battery cells are arranged in a nested configuration within the housing, maximizing space efficiency while maintaining structural integrity and safety
2Area of stationary object
If the terminal size is reduced, then mounting space efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The terminal structure merges multiple functions into a single integrated component: the terminal body provides electrical connection, the support portion provides mechanical mounting, and the extending portions provide both structural support and additional mounting options. This merging reduces the overall footprint while managing complexity through functional integration
Solution Approach 2:
The terminal structure serves multiple functions: electrical conduction, mechanical support, mounting attachment, and space optimization. The extending portions can serve as both structural elements and additional mounting points, providing multi-functionality that reduces the need for separate components
Data Source
AI summary
A battery pack includes one or more bare cells, a protective circuit module, and one or more terminals. The protective circuit module is electrically coupled to the bare cell. The one or more terminals are on a first surface of the protective circuit module. The one or more terminals are configured to be electrically coupled to an external device. In the battery pack, one of the terminals includes a support portion coupled to the protective circuit module, a pair of body portions extended in a direction away from the first surface of the protective circuit module at the support portion, and a plurality of extending portions extended in different directions from opposite sides of the pair of body portions. The extending portions extend parallel to the first surface of the protective circuit module.