Cylindrical Battery PCM Integration via Side Wall Tabs
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Solution Overview
Problem
Cylindrical secondary batteries with integrated protection circuit modules (PCMs) face issues with additional connecting terminals and wire damage due to the placement of the circuit board at the round side of the bare cell, leading to increased parts and manufacturing costs, as well as vulnerability to external shocks.
Innovation Solution
The design incorporates first and second electrode tabs that are welded to the cylindrical can's side wall, with extensions and couplers that securely attach to the circuit board, reducing the need for external wires and enhancing shock resistance by integrating the PCM directly with the battery's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the circuit board of the PCM is positioned at the round side of the bare cell, then the PCM can be integrated with the battery, but additional connecting terminals and wires are required which increase parts count and manufacturing complexity
Solution Approach 1:
The patent merges the circuit board mounting surface with the cylindrical can structure by forming a flat surface directly on the curved surface of the can. This integration eliminates the need for separate mounting brackets or additional connecting terminals, as the circuit board is directly attached to the integrated surface formed on the can itself, thereby reducing parts count while maintaining PCM integration.
2Ease of operation
If wires are used to connect the PCM to external devices, then electrical connection is achieved, but the wires are easily damaged during use
Solution Approach 1:
The patent extracts the vulnerable wire connection function and replaces it with a direct electrical connection through the integrated flat surface on the cylindrical can. By eliminating the wire intermediate connection and establishing direct electrical contact between the circuit board and the can structure, the design removes the weak point that was susceptible to damage from external shocks while preserving the electrical connection capability.
3Adaptability or versatility
If the circuit board is positioned at the round side of the bare cell, then the PCM is integrated with the battery, but the structure becomes more vulnerable to external shocks
Solution Approach 1:
The patent segments the cylindrical can structure by forming a localized flat surface on the curved surface, creating a distinct mounting zone that separates the circuit board placement area from the rest of the cylindrical structure. This segmentation allows the circuit board to be positioned on a stable, shock-resistant flat surface that is structurally integrated with the robust cylindrical can, thereby reducing vulnerability to external shocks while maintaining integration.
4Ease of manufacture
If additional connecting terminals are required for the PCM, then the battery can be assembled, but manufacturing costs increase
Solution Approach 1:
The patent merges the cylindrical can structure with the circuit board mounting surface by forming a flat surface directly on the can. This consolidation eliminates the need for separate connecting terminals, mounting brackets, and associated fasteners, thereby reducing the total number of parts while maintaining the ability to assemble the PCM with the battery, thus lowering manufacturing costs.
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 configuration reduces the number of parts and manufacturing costs while enhancing durability against external shocks by securely attaching the PCM to the cylindrical battery, minimizing wire damage and improving overall structural integrity.
Implementation Method 1
the first electrode tab is welded to the side wall of the cylindrical can
Data Source
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AI summary
A secondary battery includes a cylindrical bare cell including a cylindrical can configured as a first electrode and an electrode cap configured as a second electrode, the electrode cap coupled with the cylindrical can and a protection circuit module including a circuit board facing the electrode cap, a first electrode tab electrically connecting the circuit board to the cylindrical and a second electrode tab electrically connecting the circuit board to the electrode cap of the cylindrical bare cell.