Secondary Battery Pack PCM Mounting on Sealed Surplus Portion
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Solution Overview
Problem
The existing secondary battery pack assembly process is complex and costly due to the need for multiple insulative tapes, which also compromises mechanical strength and dimensional stability, and exposes electrode terminals, making them vulnerable to external impacts.
Innovation Solution
A secondary battery pack design where a protection circuit module (PCM) with a protection circuit board is housed in an electrically insulative case, mounted to the outer circumference of the battery cell, reducing the number of parts and using a sealed surplus portion for assembly, thereby enhancing structural stability and protecting the PCM from external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulative tapes are used to connect the PCM to the battery cell, then electrical insulation is achieved, but the assembly process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent merges the electrical insulation function and mechanical connection function into a single integrated structure. The battery case itself is designed with insulative properties and directly connects to the PCM, eliminating the need for separate insulative tapes. This consolidation reduces the number of components and simplifies the assembly process while maintaining reliable electrical insulation.
2Reliability
If multiple insulative tapes are used to connect the PCM to the battery cell, then electrical insulation is achieved, but mechanical strength and dimensional stability are compromised
Solution Approach 1:
The patent combines the insulation and structural support functions into the battery case itself. The case is designed with sufficient mechanical strength to maintain dimensional stability while providing electrical insulation. This integrated approach eliminates the weakness of using multiple thin insulative tapes that compromise mechanical strength.
3Reliability
If the battery cell is sealed completely, then safety is improved, but the PCM cannot be mounted to the outer circumference
Solution Approach 1:
The patent segments the battery case structure by creating a specific mounting region on the outer circumference where the PCM can be attached. The case maintains its sealed structure for safety while incorporating designated areas with appropriate mechanical and electrical properties for PCM integration. This segmentation allows both safety and manufacturability requirements to be satisfied simultaneously.
4Ease of operation
If electrode terminals are exposed outside for connection, then electrical connection is enabled, but vulnerability to external impact increases
Solution Approach 1:
The patent nests the electrode terminals within the battery case structure rather than exposing them externally. The terminals are positioned and protected within the case while maintaining electrical connection capability through the case wall or via protected connection points. This nesting approach shields the terminals from external impacts while preserving electrical connectivity.
Data Source
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AI summary
Disclosed herein is a secondary battery pack including a battery cell having an anode terminal and a cathode terminal formed at one face having a sealed surplus portion and a protection circuit module (PCM) electrically connected to the battery cell via the anode terminal and the cathode terminal, wherein the PCM includes a board having a protection circuit formed thereon, the board being provided with an anode terminal connection part and a cathode terminal connection part connected to the anode terminal and the cathode terminal, respectively, and a PCM case configured to receive the board through an open face thereof so that the PCM case surrounds the board. The board is coupled to the anode terminal and the cathode terminal of the battery cell via the anode terminal connection part and the cathode terminal connection part, the board is disposed in the PCM case, and the PCM case, in which the board is disposed, is mounted to the sealed surplus portion of the battery cell.