PCM Insert Injection Mold for Battery Short Circuit Prevention
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Solution Overview
Problem
Conventional battery manufacturing methods risk short circuits, deformation, and failures due to contact between the battery cell and protection circuit module (PCM) during molding, especially under high-temperature and high-pressure conditions, and require additional coating steps to prevent short circuits.
Innovation Solution
The PCM is molded separately from the battery cell using insert injection molding, with connection terminals or leads partially exposed to allow for later connection, avoiding simultaneous power application and reducing the risk of short circuits, allowing for the use of various resin types and improving separation and repairability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the battery cell and PCM are integrated with each other in the mold during manufacturing, then the battery can be assembled efficiently, but the battery cell and PCM contact the mold causing short circuit risk
Solution Approach 1:
The patent divides the manufacturing process into two separate stages: first molding the PCM independently in a separate mold, then assembling it with the battery cell in a second stage. This segmentation eliminates electrical contact between the PCM and the mold during the molding process, preventing short circuits while maintaining assembly efficiency through the pre-prepared PCM unit.
2Temperature
If the battery cell reaches high temperature during molding, then the resin cures properly, but the battery characteristics change and explosion risk increases
Solution Approach 1:
The patent performs the high-temperature molding process separately on the PCM only, before assembling it with the battery cell. This segmentation ensures that the battery cell never experiences high molding temperatures, eliminating the risk of characteristic changes or explosion while still achieving proper resin curing in the PCM.
3Manufacturing precision
If pressure is applied to the battery cell during molding, then the components are fixed in position, but vents are generated at the welding portion of the battery can
Solution Approach 1:
The patent applies molding pressure only to the PCM during the first molding stage, before the battery cell is assembled. This eliminates the problem of pressure-induced vents at the battery can welding portion, as the battery cell is not present during the pressure application phase. The PCM is then assembled with the battery cell in a low-pressure environment.
4Reliability
If the output terminal is coated to prevent short circuit, then electrical safety is improved, but worker convenience is reduced due to additional steps
Solution Approach 1:
The patent prevents short circuits by segmenting the manufacturing process so that the PCM is molded separately from the battery cell, eliminating the need for coating the output terminal. The physical separation during molding inherently prevents electrical contact, providing safety without adding operational complexity or additional coating steps.
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 method reduces the risk of electrical damage, eliminates the need for additional coating, and enhances productivity by allowing the use of different resin types and conditions, improving the stability and reliability of the battery by separating the PCM from the battery cell during molding.
Implementation Method 1
injecting a molten resin into an inner space of mold
Implementation Method 2
injecting a molten resin into an inner space of mold
Data Source
AI summary
The present invention provides a protection circuit module (PCM) insert injection mold, and a battery having the same. The PCM insert injection mold is made by inserting a PCM, including a plate having protection circuit formed thereon and connection terminals and optionally leads, with the protection circuit plate, connection terminals and leads being electrically connected, into an inner space of a mold, and injecting a molten resin into the inner space of the mold such that the leads are partially exposed to the outside where the PCM includes the leads, or such that the connection terminals are partially exposed to the outside where the PCM does not include the leads. Since the PCM is prepared by insert injection molding under the condition that the protection circuit and battery cell are not connected, i.e., that power is not applied to a battery, the PCM can be molded using general resins, is electrically stable, does not require a coating step for preventing short circuit, and is rare electrically damaged.