Flexible Substrate Protection Circuit Module for Rechargeable Battery
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Solution Overview
Problem
Existing protection circuit modules for rechargeable batteries, typically formed on rigid PCBs, face high error rates and thermal damage during soldering due to the difficulty in connecting wires, which complicates the manufacturing process.
Innovation Solution
A protection circuit module with a reinforcement unit formed on a flexible substrate, featuring separable electrode layers and a resin-molded reinforcement structure, minimizes thermal damage and error rates by allowing easier terminal connections and stable circuit support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid PCB is used for the protection circuit, then the circuit structure is stable, but the soldering process causes thermal damage to circuit elements and increases manufacturing error rate
Solution Approach 1:
The patent divides the circuit board into two separate layers: a flexible substrate for mounting circuit elements and a reinforcement unit for providing structural stability. This segmentation allows the circuit elements to be isolated from thermal damage during soldering while maintaining overall structural integrity.
Solution Approach 2:
The flexible substrate acts as an intermediary between the soldering process and the circuit elements. By performing soldering operations on the reinforcement unit rather than directly on the substrate with mounted elements, the intermediary structure prevents direct thermal exposure to sensitive circuit components.
2Stability of the object's composition
If a rigid PCB is used for the protection circuit, then the circuit structure is stable, but the wire connection process becomes difficult and increases manufacturing error rate
Solution Approach 1:
The patent segments the circuit board structure into a flexible substrate and a separate reinforcement unit with terminal connection units. This allows wire connections to be made to the exposed terminal units on the reinforcement unit, which is easier than connecting wires to a rigid PCB with through-hole mounting, while still providing structural stability.
Solution Approach 2:
Instead of connecting wires directly to the rigid PCB as in conventional designs, the patent inverts the approach by providing exposed terminal connection units on the reinforcement unit that are specifically designed for easier wire attachment, while the rigid structure supports the flexible substrate with mounted elements.
3Object-affected harmful factors
If a flexible substrate is used for the protection circuit, then thermal damage is reduced, but the circuit structure lacks stability
Solution Approach 1:
The patent merges the flexible substrate and the rigid reinforcement unit into a single integrated circuit board structure. The flexible substrate provides thermal protection for circuit elements, while the reinforcement unit provides structural stability, and their combination achieves both objectives simultaneously.
Solution Approach 2:
The circuit board is constructed as a composite structure with a flexible substrate (such as flexible PCB material) and a rigid reinforcement unit. This composite design combines the thermal benefits of flexible materials with the structural advantages of rigid materials.
4Stability of the object's composition
If a reinforcement unit is added to the flexible substrate, then structural stability is improved, but the device complexity increases
Solution Approach 1:
The patent segments the circuit board into functionally distinct units: the flexible substrate for circuit element mounting and the reinforcement unit for structural support and terminal connections. This segmentation allows each unit to be optimized for its specific function while maintaining overall simplicity.
Solution Approach 2:
The reinforcement unit serves multiple functions simultaneously: providing structural stability to the flexible substrate, facilitating wire connections through exposed terminal units, and protecting the circuit elements from thermal damage during soldering. This multi-functionality reduces the need for additional separate components.
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 flexible substrate-based protection circuit module reduces thermal strain and manufacturing errors, enabling efficient and reliable connection of terminal electrodes while preventing thermal damage to circuit elements.
Implementation Method 1
The reinforcement unit may be adhered to the opposing surface of the circuit supporting unit by an adhesive.
Implementation Method 2
The reinforcement unit may be formed on the opposing surface of the circuit supporting unit by molding a resin.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A protection circuit module of a rechargeable battery comprises a substrate formed of a flexible insulator and including a circuit supporting unit and a wiring supporting unit extending from the circuit supporting unit; a conductive circuit pattern unit formed on the circuit supporting unit; a conductive wiring unit formed on the wiring supporting unit, wherein the wiring unit is electrically connected to the circuit pattern unit and extends along the wiring supporting unit; circuit elements electrically connected to the circuit pattern unit and formed on one surface of the circuit supporting unit; and a reinforcement unit formed on an opposing surface of the circuit supporting unit and supporting the circuit supporting unit.