PTC Device Support Portion Prevents Swaying in PCM
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Solution Overview
Problem
Conventional PTC devices tend to sway or twist during mounting on Protective Circuit Modules (PCMs) or subsequent assembly processes, leading to defective connections and potential external short-circuits due to their elongated design and uneven fixation.
Innovation Solution
A PTC device design featuring a conductive plate with a support portion of the same height as the conductive layer, formed by bending one end of the plate, which is securely fixed to the PCM using an adhesive, ensuring stable electrical and physical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PTC devices are mounted using conventional surface mount technology with soldering, then electrical connection is achieved, but the device sways or twists during mounting and subsequent processes due to uneven fixation
Solution Approach 1:
The conductive plate is divided into distinct functional segments: a mounting portion for adhesive attachment to the PCM, and a support portion that extends upward to contact and stabilize the PTC device. This segmentation allows each portion to perform its specific function optimally - the mounting portion provides secure fixation while the support portion maintains device orientation.
Solution Approach 2:
The conductive plate acts as an intermediary component between the PCM and the PTC device. Rather than directly soldering the PTC device to the PCM, the conductive plate serves as a mediator that provides both electrical connection and mechanical support, eliminating the need for uneven solder fixation on both ends of the PTC device.
2Length of moving object
If PTC devices are made long to fit battery dimensions, then they can be installed in bare cells, but both ends being terminals causes twisting and external short-circuits when only one end is fixed
Solution Approach 1:
The terminal function is extracted from both ends of the PTC device and consolidated at one end only. The conductive plate provides the necessary electrical connection at the mounting end, while the support portion extends to provide mechanical stability along the length of the PTC device, eliminating the need for terminal connections at both ends.
Solution Approach 2:
The solution moves from a two-point connection approach (terminals at both ends) to a distributed support approach. The support portion of the conductive plate provides continuous mechanical support along the length of the PTC device, transitioning from discrete point contacts to extended linear support, preventing twisting while maintaining electrical connection.
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
Prevents swaying or twisting of the PTC device during assembly, thereby preventing defective connections and external short-circuits, ensuring reliable mounting and operation of the PTC device within the PCM.
Implementation Method 1
The conductive layer on the surface of the electrical terminal of the Protective Circuit Module (PCM) melts and then hardens so that the terminal of the PTC device is both electrically connected to the electrical terminal of the Protective Circuit Module (PCM) and is physically fixed thereto.
Data Source
AI summary
A Positive Temperature Coefficient (PTC) device, a Protective Circuit Module (PCM) including the PTC device, and a secondary battery including the Protective Circuit Module (PCM) are provided. A support portion is formed at one end of a conductive plate of the PTC device, a conductive layer disposed on the upper portion of the PTC main body is fixed to the Protective Circuit Module (PCM), and the support portion is fixed by a coated adhesive that is melted at a high temperature and then hardens when the high temperature is removed, thereby preventing the PTC device from swaying or twisting.