Rechargeable Battery Protective Circuit Board Resin Molding
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Solution Overview
Problem
The existing methods for fabricating rechargeable batteries are time-consuming and costly due to the manual or mechanical assembly processes, particularly for the protective circuit board portion, which involves multiple components and increases the risk of defects.
Innovation Solution
A rechargeable battery is fabricated using a protective circuit board portion formed into a single body through resin molding, with electrical terminals extending from the PCB substrate, reducing the number of components and assembly processes, and integrating major components like the PCM and PTC element into a single molded body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual or mechanical assembly processes are used for the protective circuit board portion, then the battery can be assembled with multiple components, but the fabrication time and cost increase significantly
Solution Approach 1:
The patent combines the protective circuit board, insulation plate, and base case into a single integrated protective circuit board portion through resin molding. This merging of multiple components into one unit eliminates the need for separate assembly steps, directly resolving the contradiction by maintaining functional complexity while dramatically reducing fabrication time and process complexity
Solution Approach 2:
The integrated protective circuit board portion serves multiple functions simultaneously: it provides electrical protection through the circuit board, electrical insulation through the insulation plate, and structural support through the base case. This multi-functionality in a single component allows the battery to maintain all necessary protective functions while simplifying the assembly process and reducing fabrication time
2Reliability
If multiple components are assembled manually or mechanically, then the battery functionality is complete, but the risk of defects increases
Solution Approach 1:
By merging the protective circuit board, insulation plate, and base case into a single molded component, the patent eliminates multiple assembly interfaces where defects could occur. The resin molding process creates a unified structure without seams or joints between these components, directly reducing the defect rate while maintaining all necessary protective functions
Solution Approach 2:
The patent replaces mechanical assembly processes with resin molding to create the protective circuit board portion. This substitution eliminates the need for mechanical fastening, welding, or adhesive bonding between the circuit board, insulation plate, and base case, thereby removing sources of assembly defects and improving manufacturing precision
3Ease of manufacture
If multiple separate components are used for the protective circuit board portion, then each component can be optimized independently, but the assembly process becomes more complex and costly
Solution Approach 1:
The patent merges the protective circuit board, insulation plate, and base case into a single integrated component through resin molding. This eliminates the complex assembly process of joining multiple separate components while maintaining the functional advantages of each component. The single-mold construction simplifies manufacturing by reducing the number of assembly steps, fasteners, and alignment requirements
Data Source
AI summary
A rechargeable battery, which features a simplified assembly process by reducing the number of components includes a bare cell, a body portion which is attached to one side surface of the bare cell and a protective circuit board portion which has two electrical terminals respectively electrically connected to two electrode terminals of the bare cell and formed into one single body by molding. A method of fabrication of the rechargeable battery includes forming a protective circuit board portion into one single body through resin molding, attaching the protective circuit board portion to a bare cell, and respectively electrically connecting two electrical terminals of the protective circuit board portion to two electrodes of the bare cell.