Battery Pack PCM Coupling via Insertion Grooves

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Solution Overview

Problem

The existing secondary battery pack assembly process is complex, requiring multiple parts and welding/soldering processes, leading to increased manufacturing costs and defect ratios, and lacks efficient electrical and mechanical coupling between the protection circuit module (PCM) and the battery cell.

Innovation Solution

A secondary battery pack design featuring a battery cell with coupling grooves at the electrode terminals, an insulative mounting member with exposed terminals, and a PCM with downward-protruding connection coupling members that insert into these grooves for mechanical and electrical connection, eliminating the need for nickel plates and welding/soldering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding or soldering processes are used to connect the PCM to the battery cell, then reliable electrical connection is achieved, but manufacturing complexity and defect ratio increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the welding/soldering process (thermal/mechanical system) with a mechanical insertion system. The connection coupling members with protrusions are simply inserted into the PCM, where the protrusions engage with corresponding grooves or slots to provide both mechanical support and electrical connection, eliminating the need for welding equipment and complex thermal processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the welding/soldering step from the assembly process. By designing the connection coupling members with integrated protrusions that directly engage with the PCM structure, the complex joining process is removed entirely, leaving only a simple insertion operation that achieves both mechanical attachment and electrical connectivity.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If multiple insulative mounting members or parts are used to achieve electrical connection and isolation, then safety requirements are met, but the assembly process becomes complicated and space is reduced

Engineering Contradiction:

Improveelectrical isolation safetyVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into the connection coupling members. These members simultaneously provide mechanical support (holding the PCM in position), electrical connection (through conductive protrusions engaging with the PCM), and electrical isolation (by being positioned within the insulative mounting member structure). This integration eliminates the need for separate insulative parts while maintaining safety requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection coupling members are designed as universal components that perform multiple functions: they provide structural support for the PCM, establish electrical pathways through their conductive protrusions, and work within the insulative mounting member to ensure electrical isolation. This multi-functionality reduces the total component count while meeting all safety and performance requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If welding or soldering processes are used to connect nickel plates to electrode terminals, then secure electrical connection is achieved, but manufacturing cost and defect ratio increase

Engineering Contradiction:

Improveelectrical connection strengthVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the welding/soldering process (which requires expensive equipment, skilled operators, and generates defects) with a simple mechanical insertion process. The connection coupling members with protrusions are directly inserted into the PCM, where the protrusions engage with grooves or slots to provide secure electrical connection without any thermal processing, significantly reducing manufacturing cost and defect risk.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses simple, inexpensive connection coupling members that can be easily manufactured and replaced if needed. These components are designed for single-use insertion rather than requiring expensive, precision welding operations. The simplicity of the insertion mechanism and the basic geometry of the coupling members make them cost-effective compared to welded nickel plate connections.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentEP2337121B1Secondary battery pack with a novel structure

Publication Date: 2017.06.21 LG CHEM LTD

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AI summary

Disclosed herein is a secondary battery pack including a battery cell having a pair of coupling grooves, each of the coupling grooves having a predetermined depth, an insulative mounting member mounted to the top of the battery cell, a protection circuit module (PCM) having a pair of connection coupling members protruding downward, and an insulative cap coupled to the top of the battery cell, wherein the connection coupling members are inserted into coupling grooves formed at electrode terminals of the battery cell through openings of the insulative mounting member in a state in which the insulative mounting member is mounted to the top of the battery cell, thereby achieving the coupling of the PCM to the battery cell and the insulative mounting member and the electrical connection between the battery cell and the PCM.