Protective Circuit Module Integrating PTC Device for Battery Protection
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Solution Overview
Problem
Conventional secondary batteries face challenges in mountability and configurability due to the integration of Positive Temperature Coefficient (PTC) devices and protective circuit modules, leading to delayed activation of PTC devices and inaccurate positioning of electrode terminals during resin molding, which can result in electrical disconnects and reduced battery performance.
Innovation Solution
A protective circuit module design that integrates a circuit board with a PTC device connected via serial or direct resistance welding, featuring conductive pads and leads that allow for simplified assembly and reduced heat exposure to the PTC device, ensuring accurate positioning of electrode terminals and efficient heat transfer for immediate activation of the PTC device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the PTC device and protective circuit module are mounted during pack assembly with folded electrode tabs and conductive leads, then the battery structure is compact, but the PTC device activation is delayed
Solution Approach 1:
The PTC device is pre-integrated with the protective circuit module before battery assembly, with the PTC device positioned adjacent to the module and connected via pre-positioned conductive leads. This preliminary integration ensures that when temperature rise occurs, the PTC device can activate immediately without delay from folded tabs or lead routing issues.
2Stability of the object's composition
If the protective circuit module is molded by resin to be integrated with the battery, then the structure is stable, but the electrode terminal positioning becomes inaccurate
Solution Approach 1:
The protective circuit module is designed as a separate integrated unit containing the circuit board, protection control circuit elements, and PTC device, which is then mounted as a complete assembly onto the battery. This segmentation allows the module to be manufactured and tested independently with precise internal positioning, while the battery assembly process focuses on mounting the entire module, thereby maintaining both structural stability and positioning accuracy.
3Volume of moving object
If the PTC device is connected using folded electrode tabs and conductive leads, then the volume is minimized, but the mountability and configurability deteriorate
Solution Approach 1:
The PTC device is merged with the protective circuit module into a single integrated assembly where the PTC device is positioned adjacent to the module and connected via conductive leads that are part of the module structure. This merging eliminates the need for separate mounting and connection steps, improving ease of manufacture while maintaining compact volume.
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 design enhances the mountability and configurability of PTC devices, prevents heat-induced deterioration, ensures immediate activation of the PTC device, and maintains accurate electrode terminal positioning, thereby improving the stability and performance of secondary batteries.
Implementation Method 1
a positive temperature coefficient device between the at least one protection control circuit element and the first conductive pad such that when a secondary battery temperature reaches a threshold value, resistance of the positive temperature coefficient device is increased and battery current is reduced
Implementation Method 2
A protective circuit module design that integrates a circuit board with a PTC device connected via serial or direct resistance welding, featuring conductive pads and leads that allow for simplified assembly and reduced heat exposure to the PTC device, ensuring accurate positioning of electrode terminals and efficient heat transfer for immediate activation of the PTC device
Data Source
AI summary
A protective circuit module for a secondary battery is provided including a circuit board. At least one protection control circuit element for preventing overcharge and over-discharge of the secondary battery is mounted on the circuit board. A first conductive pad is coupled to the circuit board. A positive temperature coefficient device is between the at least one protection control circuit and the first conductive pad such that when a secondary battery temperature reaches a threshold value, resistance of the positive temperature coefficient device is increased and battery current is reduced.