Pouch Battery Pack PCM Assembly With Flat Lead Connection Plate
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Solution Overview
Problem
The manufacturing process of pouch-type secondary battery packs is complicated and costly due to the need for bending and connecting protection circuit modules, which increases the number of components and installation time.
Innovation Solution
A pouch-type secondary battery pack design featuring a printed circuit board with a lead connection plate and a PCM insulation pad, where the lead connection plate is formed as a single flat sheet and easily welded, and the PCM insulation pad is made of a solvent-free hot-melt resin to simplify assembly and enhance safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connection member is used to connect the protection circuit module and battery cell, then electrical connection is achieved, but the manufacturing process becomes complicated and installation time increases
Solution Approach 1:
The patent combines the connection member and insulation member into a single integrated component. The connection member includes both the electrical connection function and the insulation function, eliminating the need for separate insulation members and reducing assembly steps.
Solution Approach 2:
The connection member is designed to perform multiple functions simultaneously: it provides electrical connection between the protection circuit module and battery cell, while also providing insulation protection. This multi-functional design reduces the total number of components needed.
2Reliability
If a conventional connection member with bent portions is used, then connection is achieved, but the number of components increases and assembly time is elongated
Solution Approach 1:
The connection member is pre-formed with the bent portion and insulation structure during manufacturing, so that no additional bending or assembly steps are required during battery pack assembly. The insulation member is pre-attached to the connection member, eliminating sequential assembly operations.
3Reliability
If the connection member is bonded to the battery cell, then electrical connection is established, but the manufacturing cost and manufacturing time increase
Solution Approach 1:
The patent extracts the insulation function from the bonding process by incorporating an insulation member onto the connection member. This allows the connection member to be bonded directly to the battery cell without requiring separate insulation bonding operations, reducing manufacturing steps and costs.
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
The design reduces component size and manufacturing costs, improves safety by eliminating harmful solvents, and enhances durability by preventing short circuits and external damage, thus simplifying the manufacturing process.
Implementation Method 1
an insulating layer formed by a solvent-free hot-melt resin
Implementation Method 2
the other surface, at least a portion of which is bonded to the electrode lead
Data Source
Figure 1
Figure 2
Figure 3~4(c)
AI summary
Disclosed is a pouch-type secondary battery pack having a simplified manufacturing process with a reduced number of components. The pouch-type secondary battery pack includes a battery cell in which an electrode assembly is sealed in a pouch exterior together with an electrolyte, the battery cell having an electrode lead formed at one side thereof; and a protection circuit module having a printed circuit board with a protection circuit formed thereon and a lead connection plate formed at one surface of the printed circuit board so that the printed circuit board is electrically connected to the electrode lead of the battery cell, the protection circuit module having an exposing portion formed at the other surface of the printed circuit board to expose at least a portion of the lead connection plate.