Cylindrical Battery PCM Integration via Electrode Tab Merging
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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
A secondary battery design featuring a cylindrical bare cell with a PCM coupled in a way that reduces the number of parts and manufacturing costs, utilizing first and second electrode tabs with extensions and couplers to securely connect the circuit board to the cylindrical can, and an auxiliary tab for parallel configurations, enhancing durability against external shocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the circuit board of the PCM is positioned at the round side of the cylindrical bare cell, then the PCM can be integrated with the bare cell, but additional connecting terminals and wires are required which increase parts count and manufacturing cost
Solution Approach 1:
The patent merges the connecting terminal function directly into the electrode tab structure. The electrode tab serves dual purposes: as an electrical conductor connecting the electrode to the circuit board, and as the mounting structure for the PCM. This eliminates the need for separate connecting terminals and reduces wire usage, directly addressing the contradiction by reducing parts count while maintaining manufacturability.
Solution Approach 2:
The electrode tab is designed to perform multiple functions simultaneously: electrical conduction, mechanical support, and PCM mounting. By making the electrode tab universal for both electrical and structural purposes, the patent reduces the overall number of components needed in the battery assembly, thereby reducing manufacturing cost and complexity.
2Reliability
If the circuit board of the PCM is positioned at the round side of the cylindrical bare cell, then the PCM can be integrated with the bare cell, but the wires connecting the circuit board to connecting terminals are easily damaged during use
Solution Approach 1:
The patent extracts the wire connection from the system by eliminating the need for separate connecting terminals. The electrode tab directly serves as the connection point, removing the vulnerable wire-to-terminal junctions that are prone to damage from external shocks. This extraction of the problematic wire connection element directly improves reliability.
Solution Approach 2:
Instead of using wires to connect the circuit board to separate terminals, the patent inverts the approach by having the electrode tab directly contact the circuit board. This reversal of the connection methodology eliminates the wire vulnerability to external shock while maintaining the necessary electrical connection.
3Ease of manufacture
If additional connecting terminals and wires are used to connect the PCM to external devices, then the PCM can be connected to the cylindrical bare cell, but the number of parts and manufacturing costs increase
Solution Approach 1:
The patent combines the connecting terminal function with the electrode tab, creating a unified structure that serves both purposes. This merging eliminates the need for additional connecting terminals and reduces wire usage, directly reducing parts count and simplifying the connection structure while maintaining ease of operation.
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
The design reduces the number of parts and manufacturing costs while enhancing durability against external shocks, ensuring secure connections and stable operation of the secondary battery.
Implementation Method 1
the first electrode tab is welded to the side wall of the cylindrical can
Implementation Method 2
a label wrapped around the outer surface of the cylindrical can and adhered by an adhesive material
Data Source
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.