Flush-Mounted Protection Circuit Module for Compact Battery Packs
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Solution Overview
Problem
The increasing demand for smaller, lightweight rechargeable battery packs for portable electronic devices is hindered by the need to minimize the size of the protection circuit module, which is typically bulky due to its external components and mounting configurations.
Innovation Solution
A protection circuit module design where the protection circuit part is mounted flush with the inner surface of the protection circuit board, either in a depression or through-hole, reducing overall thickness and allowing for a more compact form factor by integrating the lead frame with the circuit pattern on the board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the protection circuit part is mounted on the outer surface of the protection circuit board, then the electrical connection is simple, but the overall thickness and size of the battery pack increases
Solution Approach 1:
The protection circuit part is inserted into a hole formed in the protection circuit board, with its outer surface substantially coplanar with the inner surface of the board. This nesting configuration embeds the protection circuit part within the board structure, reducing the overall thickness and volume of the battery pack while maintaining electrical connection functionality through the lead frame and circuit pattern integration.
Solution Approach 2:
The mounting approach transitions from a two-dimensional surface mounting to a three-dimensional embedded configuration. By forming a hole through or in the protection circuit board and inserting the protection circuit part into this hole, the design utilizes the depth dimension to achieve compact integration, reducing the protruding thickness while maintaining all necessary electrical connections.
2Weight of moving object
If the protection circuit module uses a bulky mounting configuration, then the electrical connection is robust, but the battery pack cannot be made small and lightweight
Solution Approach 1:
The lead frame of the protection circuit part is electrically connected to the circuit pattern on the protection circuit board through soldering, merging the electrical connection functions into a single integrated structure. This combined approach maintains robust electrical connectivity while eliminating the need for separate bulky mounting hardware, thereby reducing the overall weight of the battery pack.
3Volume of moving object
If the protection circuit part is inserted upside down in the hole, then the space utilization is maximized, but the soldering process becomes more complex
Solution Approach 1:
The protection circuit part is inserted upside down into the hole formed in the protection circuit board, with its outer surface substantially coplanar with the inner surface of the board. This inverted insertion orientation maximizes space utilization by allowing the lead frame to extend toward the inner surface for soldering, while the bulk of the protection circuit part occupies the hole space, achieving compact volume efficiency.
Data Source
AI summary
A protection circuit module and a rechargeable battery pack including the PCM. The battery pack includes: an electrode assembly, which has a positive electrode plate, a separator, and a negative electrode plate; a case to house the electrode assembly and an electrolyte; and the protection circuit module. The protection circuit module includes: a protection circuit board having an inner surface that faces the electrode assembly and an opposing outer surface; and a protection circuit part mounted in a hole formed in the inner surface of the protection circuit board, such that the protection circuit board is flush with the inner surface of the protection circuit board.