PCM Assembly with Exposed Connection Members for Battery Pack
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Solution Overview
Problem
The existing secondary battery packs face challenges with complex assembly processes, high defect rates due to numerous welding or soldering steps, and reduced capacity due to the large number of parts and space required for connection members, which complicates the manufacturing of lithium secondary batteries with high energy density and safety concerns.
Innovation Solution
A secondary battery pack design featuring a PCM assembly with connection members coupled to the bottom of the PCM, an insulative mounting member, and an insulative cap, where connection members are exposed upward for simplified electrical connections, reducing the number of parts and assembly complexity, and utilizing surface mount technology (SMT) for accurate and reliable coupling, thereby minimizing internal resistance changes and external impact risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulative mounting members and parts are used to achieve electrical connection and isolation, then safety and electrical isolation are improved, but device complexity and assembly process complexity increase
Solution Approach 1:
The patent combines multiple insulative mounting members into a single integrated insulative mounting member that performs both electrical isolation and mechanical support functions. This single component integrates the functions of previously separate insulative parts, reducing assembly complexity while maintaining electrical isolation safety.
Solution Approach 2:
The insulative mounting member is designed to serve multiple functions simultaneously: it provides electrical isolation between conductive parts, mechanically supports the connection members, and facilitates the assembly process. This multi-functional design eliminates the need for multiple specialized components.
2Reliability
If multiple welding or soldering processes are used to connect PCM to battery cell, then electrical connection reliability is improved, but manufacturing precision requirements and defect possibilities increase
Solution Approach 1:
The patent extracts the connection members from the PCM assembly and makes them independently accessible. This allows the electrical connection to be established separately from the PCM assembly process, eliminating the need for precise welding or soldering of multiple small components and reducing defect possibilities.
Solution Approach 2:
The connection members are pre-positioned and exposed upward from the PCM assembly before final assembly with the battery cell. This preliminary arrangement allows for easier and more reliable electrical connection with reduced precision requirements, as the connection points are already in the correct position and orientation.
3Reliability
If numerous parts are loaded on battery cell top to ensure safety and connection, then reliability is improved, but battery capacity and energy density decrease
Solution Approach 1:
The patent merges multiple safety and connection functions into fewer integrated components. The single insulative mounting member combines electrical isolation, mechanical support, and structural stabilization functions, reducing the number of parts on the battery cell top and increasing available space for battery capacity.
Solution Approach 2:
The patent segments the connection members from the main PCM body, allowing them to be independently positioned and connected. This segmentation enables more efficient space utilization on the battery cell top, as connection members can be arranged optimally without requiring additional insulative structures.
Data Source
AI summary
Disclosed herein is a secondary battery pack including a battery cell, and a protection circuit module (PCM) assembly, configured in a specific structure, coupled to the top of the battery cell. The secondary battery pack includes a battery cell having an electrode assembly mounted in a battery case together with an electrolyte in a sealed state, a protection circuit module (PCM) assembly including a PCM and connection members, the PCM assembly being provided with a through-hole for connection, an insulative mounting member mounted at the top of the battery cell, an insulative cap coupled to an upper end of the battery cell. One of the connection members, i.e., the connection member (A), protrudes from one end of the PCM assembly such that a region of the connection member (A) electrically connected to the battery cell is exposed upward from the PCM assembly. The other connection member, i.e., the connection member (B), is coupled to the bottom of the PCM such that at least a portion of the connection member (B) is exposed upward from the PCM assembly through the through-hole for connection. The electrical connection between the connection members and the electrode terminals of the battery cell is achieved at the top of the PCM while the insulative mounting member and the PCM assembly are loaded on the battery cell.