Secondary Battery Pack Top Cap Assembly Integration
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Solution Overview
Problem
The existing methods for assembling secondary battery packs are complex, leading to high defect ratios and increased manufacturing costs due to the need for multiple welding and soldering processes, as well as limited space for assembly, which complicates the integration of safety elements like the protection circuit module (PCM) and insulative mounting members.
Innovation Solution
A secondary battery pack design that integrates connection members A and B with a protection circuit module (PCM) and insulation tape, where connection member A is bent perpendicularly and welded to the first electrode terminal, and connection member B is connected to the second electrode terminal via a safety element, allowing for simplified assembly and reduced defect ratios, while maintaining electrical insulation and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple welding and soldering processes are used to connect PCM and insulative mounting members to battery cell, then reliable electrical connection is achieved, but assembly process complexity increases and defect ratio increases
Solution Approach 1:
The patent combines multiple separate components (connection members and insulative mounting members) into a single integrated top cap structure. The top cap directly contacts the electrode terminals and provides both electrical connection and insulation functions, eliminating the need for separate welding and soldering processes while maintaining connection reliability and reducing assembly complexity
Solution Approach 2:
The top cap serves multiple functions simultaneously: it provides electrical connection to electrode terminals, provides electrical insulation, and structurally supports the PCM. This multi-functional design replaces multiple specialized components, simplifying the assembly process while ensuring reliable electrical connections
2Reliability
If multiple separate components (connection members and insulative mounting members) are used to connect PCM to battery cell, then electrical insulation is maintained, but assembly space requirements increase
Solution Approach 1:
The patent merges the insulative mounting member and connection members into a single integrated top cap structure. This consolidation maintains the necessary electrical insulation properties while significantly reducing the total volume required for assembly, as the insulating material and conducting elements are combined in a compact unified structure
Solution Approach 2:
The design nests the electrical connection elements within the insulative top cap structure. The connection members are positioned and secured within the insulating material, allowing the conducting and insulating functions to occupy overlapping spatial volumes rather than requiring separate dedicated spaces for each function
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 design simplifies the assembly process, reduces manufacturing costs, and enhances the quality and stability of the battery pack by minimizing defects and optimizing the use of conventional components and assembly methods, while improving safety through direct connections and sensitive temperature response.
Implementation Method 1
one end of the connection member A bent perpendicularly to the other end of the connection member A coupled to the terminal connection part formed at the bottom of the PCB being electrically connected to the first electrode terminal by welding
Data Source
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AI summary
Disclosed herein is a secondary battery pack including a battery cell having a first electrode terminal, a second electrode terminal and a pair of coupling grooves formed at the top of a battery case, a protection circuit module (PCM) including a protection circuit board (PCB), connection members A and B connected to the first electrode terminal and the second electrode terminal, respectively, and a safety element, and an electrically insulated top cap having through holes communicating with the respective coupling grooves, wherein one end of the connection member A is coupled to a terminal connection part formed at the bottom of the PCB, a connection portion of the connection member B connected to the second electrode terminal of the battery cell is located at the bottom of the PCB, the connection member B being electrically connected to the second electrode terminal via the safety element, coupling members are coupled into the respective coupling grooves of the battery cell through the through holes of the top cap in a state in which the PCM and the top cap are disposed at the top of the battery cell, one end of the connection member A bent perpendicularly to the other end of the connection member A coupled to the terminal connection part formed at the bottom of the PCB being electrically connected to the first electrode terminal by welding, and an insulation tape is attached to the bottom of the PCB in a state in which portions of the connection members A and B connected to the electrode terminals of the battery cell are exposed, the PCM and the insulation tape being mounted in the top cap.