PCM Mechanical Coupling for Battery Pack Assembly
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Solution Overview
Problem
Existing protection circuit modules for lithium secondary batteries require skilled labor and large working spaces for welding or soldering, leading to safety risks and low coupling forces with battery cells, especially when using plate-shaped electrode terminals.
Innovation Solution
A protection circuit module with specific-structure connecting and coupling members that allow for mechanical and electrical coupling without welding or soldering, utilizing complementary coupling parts like protrusions and catching jaws to increase the coupling force and prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or soldering is used to connect the protection circuit module to the battery cell, then the coupling force is improved, but the requirement for skilled labor and large working space increases, and safety risks increase
Solution Approach 1:
The patent replaces the welding/soldering process (thermal/mechanical system requiring skilled labor) with a mechanical coupling system using connecting members and coupling members. The connecting members with protrusions fit into corresponding recesses of the battery cell, creating a secure mechanical connection without requiring welding skills or specialized equipment.
Solution Approach 2:
The patent introduces connecting members as intermediary components between the protection circuit module and the battery cell. These connecting members serve as mediators that provide both electrical connection and mechanical coupling, eliminating the need for direct welding between the PCM and battery cell while maintaining strong coupling force.
2Reliability
If welding or soldering is used to connect the protection circuit module to the battery cell, then the electrical connection is improved, but the safety risk increases due to potential short circuits from physical impacts
Solution Approach 1:
The patent designs the connecting members with protrusions that fit into recesses, creating a cushioning effect that absorbs physical impacts before they can reach the electrical connection points. This beforehand cushioning protects the electrical connection from damage due to external impacts, preventing short circuits and safety hazards.
Solution Approach 2:
The patent segments the connection system into separate functional components: connecting members for electrical connection and coupling members for mechanical coupling. This segmentation allows the electrical connection to be protected from physical impacts by the mechanical coupling structure, reducing safety risks while maintaining reliable electrical connectivity.
3Ease of manufacture
If additional members are connected to the battery cell in a coupling fashion without welding, then the problems from welding are solved, but the coupling force decreases and the possibility of separation increases
Solution Approach 1:
The patent employs asymmetric design in the connecting members, with protrusions on one side fitting into corresponding recesses on the battery cell. This asymmetric configuration provides strong directional coupling force while maintaining ease of assembly, as the asymmetric shapes guide the assembly process and prevent misalignment, ensuring secure connection without requiring welding.
4Reliability
If the protection circuit is connected to the battery cell using plate-shaped electrode terminals, then the electrical connection is established, but the coupling force is low and the connecting force is insufficient
Solution Approach 1:
The patent merges the electrical connection function and mechanical coupling function into a single integrated system. The connecting members with protrusions serve both to conduct electricity and to provide strong mechanical coupling, eliminating the need for separate electrical connectors and mechanical fasteners, thereby increasing both electrical reliability and mechanical strength simultaneously.
Data Source
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Figure 4~5
AI summary
Disclosed herein is a protection circuit module (PCM) including a protection circuit for controlling overcharge, overdischarge, and overcurrent of a battery. The protection circuit module includes a pair of connecting members, which are mounted to a rectangular lower end of the PCM and electrically connected to a protection circuit, and a pair of coupling members coupled to the corresponding connecting members while plate-shaped electrode terminals of a battery cell are interposed between the connecting members and the coupling members, and a battery pack including the protection circuit module, which is electrically connected to a battery cell. According to the present invention, a welding or soldering process, which requires a large amount of time and a high degree of technical skill to manufacture a battery pack, is not necessary, the coupling force between the battery cell and the PCM is increased, and the inner space of the battery pack is maximally utilized.