Protective Circuit Module Antenna Coupling
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Solution Overview
Problem
The coupling between secondary battery packs and loop antennas, particularly those manufactured with injection molding materials, often results in increased contact resistance due to deficient electrical connections.
Innovation Solution
A protective circuit module with an insulating substrate and a printed circuit pattern, where a loop antenna is electrically connected to the printed circuit pattern, either by being inserted among layers of the substrate or coupled using a coupling member, enhancing the coupling force and reducing interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a loop antenna is soldered to a protective circuit module using injection molding material, then the antenna can be integrated with the circuit module, but the coupling between the antenna and the circuit pattern becomes deficient, leading to increased contact resistance
Solution Approach 1:
A separate coupling member is introduced as an intermediary component between the loop antenna and the protective circuit module. This coupling member includes a coupling plate with a through-hole that receives the antenna, and a coupling protrusion that electrically connects to the printed circuit pattern. The intermediary structure provides dedicated electrical contact points, ensuring reliable coupling without compromising the integration benefit of injection molding.
Solution Approach 2:
The electrical connection structure is segmented into distinct functional parts: the loop antenna, the coupling member with coupling plate and coupling protrusion, and the protective circuit module. This segmentation allows each component to be optimized independently - the coupling member can be designed with specific electrical contact features while the overall assembly remains integrable through injection molding processes.
2Reliability
If traditional soldering methods are used to connect the loop antenna to the printed circuit pattern, then electrical connection can be achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The traditional soldering (thermal/mechanical) process is replaced with a mechanical coupling system. The coupling member uses physical insertion and engagement features (through-hole for antenna, coupling protrusion for circuit connection) to establish electrical contact without requiring soldering. This substitution eliminates complex thermal processes and reduces manufacturing steps while maintaining reliable electrical connection.
Solution Approach 2:
The coupling member is designed to automatically establish electrical connections through its structure. The coupling protrusion naturally aligns with and contacts the printed circuit pattern when the antenna is inserted, creating self-aligning electrical contact that does not require additional soldering operations or complex alignment procedures.
Data Source
AI summary
A protective circuit module including: an insulating substrate including a plurality of layers; first and second printed circuit patterns disposed between the plurality of layers of the insulating substrate; a loop antenna electrically coupled to the first printed circuit pattern; and a wireless charging portion spaced apart from the loop antenna and electrically coupled to the second printed circuit pattern, wherein ends of the loop antenna and ends of the wireless charging portion are between the plurality of layers of the insulating substrate.