Prismatic Battery Pack With Bent Tabs And Leads
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Solution Overview
Problem
Existing battery packs face challenges in achieving compactness and high space utilization while ensuring stable electrical connections for medium-sized or large-sized electronic devices, which require multiple batteries connected in series and/or parallel.
Innovation Solution
A battery pack design featuring prismatic unit batteries connected in parallel using a connecting substrate with bent tabs and leads, a protection circuit module, and a temperature device, allowing for easy and stable electrical connections through simple welding, maximizing space utilization and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple batteries are connected in series and/or parallel to provide large capacity and power, then the power and capacity requirements are met, but the battery pack size and complexity increase
Solution Approach 1:
The patent transitions from planar arrangement to three-dimensional spatial arrangement by bending tabs upward and leads in multiple directions, allowing components to be positioned in vertical and lateral dimensions rather than only on a flat surface, thus maximizing space utilization
Solution Approach 2:
The connecting substrate and protection circuit module are nested adjacent to the battery cells, with tabs and leads routing connections through compact three-dimensional paths that allow components to occupy overlapping or adjacent spatial volumes
2Volume of moving object
If traditional flat connections are used, then manufacturing is simple, but space utilization is low and the battery pack cannot be miniaturized
Solution Approach 1:
The tabs and leads are designed with bent configurations rather than rigid flat connections, allowing the connection structure to adapt to three-dimensional spatial requirements while maintaining electrical connectivity and mechanical stability
Solution Approach 2:
The connection structure extends from two-dimensional planar arrangement to three-dimensional configuration by bending tabs upward from the battery surface and routing leads through multiple spatial dimensions to reach the protection circuit module
3Reliability
If the connecting substrate and protection circuit module are positioned away from batteries, then electrical connections are stable, but the battery pack cannot be miniaturized
Solution Approach 1:
The protection circuit module is positioned nested adjacent to the battery cells rather than separated, with leads routing connections through compact three-dimensional paths that maintain electrical reliability while minimizing overall pack dimensions
Solution Approach 2:
The leads are bent to extend in multiple directions and dimensions, allowing the protection circuit module to be positioned in three-dimensional space adjacent to the batteries rather than requiring planar separation, thus achieving both compactness and stable connections
Data Source
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AI summary
Provided is a battery pack (10) that includes: unit batteries (100) disposed in parallel with each other and the unit batteries (100) are prismatic type; a connecting substrate (200) for electrically coupling the unit batteries (100); a plurality of tabs (300) which extend from the connecting substrate (200), electrically connect the unit batteries (100) and the connecting substrate (200), and are bent so that the connecting substrate (200) is adjacently disposed to first surfaces of the unit batteries (100); a protection circuit module (400) electrically connected with the connecting substrate (200); and a lead (500) which extends from the protection circuit module (400), electrically connect the connecting substrate (200) and the protection circuit module (400) and are bent so that the protection circuit module (400) is adjacently disposed to second surfaces of the unit batteries (100).