Battery Protection Circuit Module Package with Insert Injection Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery protection circuit devices for mobile devices, such as lithium ion batteries, face challenges in achieving a small size due to the large space occupied by printed circuit boards (PCBs) and complex electrical connections, which complicates integration and increases the risk of overheating and explosion.
Innovation Solution
A battery protection circuit module package is created using a lead frame with protection circuit elements and an encapsulant, where the module is produced through insert injection molding, eliminating the need for a PCB and simplifying connections by exposing lead frame terminals, and a holder is coupled to the module using the same process, allowing direct connection to battery core pack electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a printed circuit board (PCB) is used for the protection circuit device, then the circuit components can be mounted and connected, but the overall size of the battery pack increases due to the large space occupied by the PCB
Solution Approach 1:
The invention extracts and eliminates the PCB from the protection circuit device structure. Instead of mounting components on a PCB, the patent uses a direct mounting structure where the protection circuit IC is mounted on a substrate without requiring a traditional PCB, thereby removing the source of excessive space occupation while maintaining component mounting and connection capabilities
Solution Approach 2:
The invention merges multiple functions into a integrated structure. The protection circuit device is designed as a compact unit where the substrate, protection circuit IC, terminal electrodes, and connection terminals are combined into a single integrated assembly that performs both circuit protection and electrical connection functions without requiring separate PCB and connection components
2Reliability
If additional wires, wire bonding, or exposed terminals are used to electrically connect the protection circuit device to battery terminals, then electrical connection can be achieved, but the manufacturing process becomes complicated and difficult
Solution Approach 1:
The invention extracts and eliminates the need for additional wires and wire bonding processes. The terminal electrodes are directly exposed on the substrate, allowing for direct electrical connection to battery terminals without requiring separate wiring steps, thus simplifying the manufacturing process while maintaining reliable electrical connection
Solution Approach 2:
The terminal electrodes are pre-configured and exposed on the substrate during the initial assembly process. This preliminary arrangement of electrical terminals eliminates the need for subsequent wiring or connection steps, making the manufacturing process simpler and more straightforward
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 enables high integration and size reduction of battery packs, simplifies manufacturing, reduces costs, and enhances coupling forces, thereby improving the quality and safety of the battery packs.
Implementation Method 1
disposing the basic package in a first injection mold and injecting a melt of resin into the first injection mold to perform an insert injection molding process
Implementation Method 2
the encapsulant and a holder simultaneously produced by disposing the basic package in a first injection mold and injecting a melt of resin into the first injection mold to perform an insert injection molding process
Data Source
AI summary
A battery pack includes a battery protection circuit module package coupled with a holder. The protection circuit module includes a basic package including a lead frame having a plurality of leads spaced apart from each other, and protection circuit elements provided on the lead frame, and an encapsulant and a holder simultaneously produced by disposing the basic package in a first injection mold and injecting a resin melt into the first injection mold to perform an insert injection molding process. The encapsulant encapsulates the protection circuit elements to expose parts of the lead frame, wherein the encapsulant and the basic package configure the battery protection circuit module package, and wherein the holder is coupled to the battery protection circuit module package due to the insert injection molding process.