Secondary Battery Wire Routing Through PCB Side Wall

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing connection methods for wires to protection circuit modules (PCMs) in secondary batteries are prone to separation, leading to insufficient tensile strength, which can result in damage during assembly and usage.

Innovation Solution

The implementation of a secondary battery design where wires are connected to the output terminals at the underside of a printed circuit board (PCB), wrapping around the PCB's side wall, with cut-out regions and spacers to secure the wires, enhancing tensile strength and preventing interference or damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If wires are connected directly to output terminals using traditional methods, then the connection process is simple, but the tensile strength of the connection is insufficient and wires may separate easily

Engineering Contradiction:

Improvetensile strength of wire connectionVSAvoidcomplexity of connection structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The wire connection is moved from a planar arrangement to a three-dimensional arrangement by routing the wire through the thickness direction of the PCB. The wire enters from one surface, passes through the PCB, and exits from the other surface, creating a dimensional transition that significantly enhances connection strength while maintaining structural simplicity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The PCB itself serves as an intermediary structure that reinforces the wire connection. By routing the wire through the PCB thickness and securing it with conductive adhesive on both surfaces, the PCB acts as a mechanical and electrical mediator that distributes stress and prevents wire separation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If wires are routed through the PCB thickness direction, then the tensile strength increases significantly, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvetensile strength of wire connectionVSAvoidease of wire connection process

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The wire routing process is merged with the PCB manufacturing process. The wire is embedded within the PCB structure during assembly, combining the mechanical support function of the PCB with the electrical connection function of the wire in a single integrated structure, thereby simplifying the overall manufacturing process

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The PCB structure itself provides the reinforcement and securing mechanism for the wire connection. The conductive adhesive on both surfaces of the PCB automatically secures the wire when it passes through, making the PCB self-sufficient in providing both electrical and mechanical functions without requiring additional external components

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP2378594B1Secondary battery

Publication Date: 2014.12.17 SAMSUNG SDI CO LTD

Figure 1
Figure 2
Figure 3~4

AI summary

A second battery is provided. Since a plurality of wires electrically connected to the output terminals of a PCB are installed surrounding at least a part of the PCB, the tensile strength of the wires may be improved.