PCM Battery Connection Structure Reducing Welding Steps
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Solution Overview
Problem
The conventional electrical connection process between a protective circuit module (PCM) and a battery cell is complex, requiring multiple welding steps and components, which increases assembly time and the risk of defective connections and foreign substance ingress, leading to potential battery malfunction or damage.
Innovation Solution
An electrical connection structure using an insulating body with cathode and anode leads that are welded to the battery cell's terminals and physically contact the PCM's taps, reducing the number of welding operations and eliminating the need for additional insulating members and side grooves, thereby simplifying the assembly process and enhancing connection stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding method is used to connect electrode leads to both battery cell terminals and PCM taps, then reliable electrical connection is achieved, but the number of welding steps and assembly time increase significantly
Solution Approach 1:
The electrical connection is divided into two separate functions: the electrical connection member handles connection to the battery cell terminals through welding, while the PCM connection is achieved through mechanical engagement with contact portions. This segmentation eliminates the need for welding at the PCM interface, reducing assembly steps while maintaining connection reliability.
Solution Approach 2:
The electrical connection member acts as an intermediary component between the battery cell and PCM. It includes welded electrode leads for battery cell connection and contact portions for PCM engagement, serving as a mediator that simplifies the overall connection process by consolidating multiple functions into a single component.
2Reliability
If multiple welding operations are performed for electrical connection, then connection stability is improved, but the complexity of the assembly process and risk of defects increase
Solution Approach 1:
The connection process is segmented into welding operations only for the electrical connection member to the battery cell terminals, while the PCM connection is achieved through mechanical engagement. This reduces the number of welding operations and simplifies the overall assembly process while maintaining connection stability.
Solution Approach 2:
Instead of welding the PCM to the battery cell terminals directly (conventional method), the invention inverts the approach by having the electrical connection member weld to the battery cell terminals and then mechanically engage with the PCM. This inversion simplifies the welding process while maintaining connection reliability.
3Ease of manufacture
If side grooves are formed on battery cap for welding access, then electrode leads can be welded to PCM taps, but foreign substances can ingress and cause battery malfunction
Solution Approach 1:
The invention extracts the welding operation from the battery cap area by performing welding only on the electrical connection member, which is positioned away from the battery cap sealing surface. The PCM connection is achieved through mechanical engagement rather than welding, eliminating the need for side grooves and preventing foreign substance ingress pathways.
Solution Approach 2:
The electrical connection member serves as an intermediary that enables welding to occur at a location accessible from the side surface without requiring grooves in the battery cap. The contact portions of the electrical connection member engage with the PCM taps through mechanical contact, eliminating the need for welding at the battery cap interface and preventing foreign substance ingress.
4Reliability
If additional insulating members are used to prevent short circuit, then electrical insulation is improved, but the number of components and assembly steps increase
Solution Approach 1:
The electrical connection member integrates multiple functions into a single component: it provides electrical connection to the battery cell terminals through welded electrode leads, provides mechanical engagement with the PCM through contact portions, and provides electrical insulation through its insulating body. This merging eliminates the need for separate insulating members and reduces the total number of components.
Solution Approach 2:
The electrical connection member is designed as a multi-functional component that simultaneously performs electrical connection, mechanical engagement, and electrical insulation functions. This universality reduces the number of separate components needed while maintaining the required electrical insulation and connection reliability.
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 significantly reduces the number of assembly steps and time, lowers the risk of defects and foreign substance ingress, and enhances the reliability of the battery pack by simplifying the connection process and improving the mechanical engagement between the PCM and the battery cell.
Implementation Method 1
a cathode lead and an anode lead mounted on the insulating body in a state of being electrically insulated from each other, wherein one or both of the cathode lead and the anode lead are welded to associated electrode terminals of the battery cell, and wherein the cathode and anode leads are connected in a contact state to associated electrode taps of the PCM
Data Source
AI summary
An electrical connection structure, and a secondary battery pack using the same are disclosed. The structure comprises an electrical connection member which includes an insulating body for insulating a PCM from a battery cell, and cathode and anode leads mounted on the insulating body in a state of being electrically insulated from each other. One or both of the cathode and anode leads are welded to associated electrode terminals of the battery cell. The cathode and anode leads are connected in a contact state to associated electrode taps of the PCM when engaging the PCM to the battery cell. The connection structure allows only the electrode leads to be welded to the battery cell, and allows the electrode terminals to be connected to the electrode taps through contact without an additional welding operation, thereby remarkably reducing the number of assembling steps, lowering manufacturing costs and preventing malfunction.