Battery Protection Circuit Module Package Using Lead Frame
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Solution Overview
Problem
Conventional battery protection circuits are large in size and complex to manufacture due to the use of printed circuit boards, making them unsuitable for compact battery packs and requiring additional processes for mounting and connection.
Innovation Solution
A battery protection circuit module package using a lead frame with a PTC structure, encapsulant, and surface-mounted protection IC and FETs, eliminating the need for a printed circuit board by using bonding wires or ribbons for electrical connections, and optionally integrating a flexible printed circuit board for direct connection to a main board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional protection circuit using PCB, protection IC, FET, resistors, and capacitors is used, then the protection function is achieved, but the battery pack size becomes excessively large
Solution Approach 1:
The patent merges the protection IC, FET, resistors, capacitors, and connection terminals into a single integrated lead frame structure. The lead frame simultaneously serves as the circuit board, housing, and electrical connection element, eliminating the need for separate PCB and component mounting, thereby dramatically reducing battery pack size while maintaining protection functionality.
Solution Approach 2:
The lead frame is designed to perform multiple functions: it acts as the structural support, the circuit board for mounting protection components, the electrical connection terminal, and the housing for the protection circuit. This multi-functionality reduces the number of separate components needed, achieving size reduction without compromising protection capability.
2Reliability
If a conventional protection circuit with separate components is used, then the protection function is achieved, but the manufacturing process becomes complex with additional mounting steps
Solution Approach 1:
The patent combines the circuit board, mounting structure, and connection terminals into a single lead frame component. This integration eliminates multiple manufacturing steps including PCB fabrication, component mounting, wire bonding, and terminal connection, simplifying the manufacturing process to primarily involve mounting the lead frame and encapsulating the components.
Solution Approach 2:
The lead frame is designed with segmented regions including a circuit board region for mounting components, a housing region for protection, and terminal regions for electrical connection. This segmentation allows for optimized manufacturing of each region while maintaining overall integration, reducing manufacturing complexity.
3Reliability
If protection IC, FET, resistors, and capacitors are mounted on PCB, then the protection circuit function is achieved, but the device complexity increases due to multiple connection processes
Solution Approach 1:
The patent merges all electrical connections into the lead frame structure itself. The lead frame provides direct electrical pathways between the protection components and external terminals, eliminating the need for separate wire bonding or PCB trace connections, thereby reducing device complexity while maintaining full protection circuit functionality.
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 solution achieves high integration and size reduction, simplifying the manufacturing process and reducing the complexity of connections, enabling more compact and efficient battery protection systems.
Implementation Method 1
battery protection circuit devices mounted on the lead frame and including a positive temperature coefficient (PTC) structure
Data Source
AI summary
Provided are a battery protection circuit module package capable of achieving high integration and size reduction, and a battery pack and an electronic device including the same. The battery protection circuit module package includes a lead frame including a plurality of leads space apart from each other, and capable of being coupled and electrically connected to electrode tabs of a battery cell, battery protection circuit devices mounted on the lead frame and including a positive temperature coefficient (PTC) structure, and an encapsulant for encapsulating the battery protection circuit devices to expose a part of the lead frame.