Externally-attached PTC Element for Tubular Battery
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Solution Overview
Problem
The existing externally-attached PTC elements for tubular batteries require additional components and processes that increase costs and hinder downsizing due to the need for lead wires and complex mounting structures, which can lead to electrical contact issues and short-circuits.
Innovation Solution
An externally-attached PTC element design featuring a bottom plate and top panel with a lead terminal shape, where the PTC element is sandwiched between them, allowing direct attachment to a tubular battery's electrode terminal with minimal additional components and reduced space requirements, using spot welding or reflow soldering for secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead wires and complex mounting structures are used for externally-attached PTC elements, then reliable electrical connection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the PTC element with the electrode terminal structure by integrating the PTC element directly into the terminal assembly. The terminal includes a terminal body with a through-hole where the PTC element is positioned, and contact pieces establish electrical connection through the PTC element. This integration eliminates the need for separate lead wires and complex mounting structures, reducing device complexity while maintaining reliable electrical connection.
2Strength
If lead wires and additional components are used for PTC element attachment, then secure mounting is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines the PTC element mounting function with the existing electrode terminal structure. The terminal body incorporates a through-hole for positioning the PTC element, and contact pieces are integrated to establish electrical connection. This eliminates the need for additional lead wires and mounting components, reducing manufacturing cost while ensuring secure mounting through the integrated structure.
3Reliability
If conventional externally-attached PTC element structures are used, then current cut-off function is achieved, but implementation space increases
Solution Approach 1:
The patent nests the PTC element within the electrode terminal structure. The terminal body contains a through-hole that accommodates the PTC element, and contact pieces are positioned to establish electrical connection through the PTC element. This nested arrangement allows the PTC element to be housed within the existing terminal footprint, reducing the overall implementation space while maintaining the current cut-off function.
4Ease of manufacture
If simple PTC element attachment is used, then manufacturing cost is reduced, but electrical contact reliability may deteriorate
Solution Approach 1:
The patent merges the PTC element with the electrode terminal structure through integration. The terminal body includes a through-hole for positioning the PTC element, and contact pieces are integrated to establish reliable electrical connection through the PTC element. This integrated design eliminates the need for additional lead wires and mounting components, reducing manufacturing cost while ensuring reliable electrical contact through the built-in connection structure.
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 reduces costs and implementation space, enabling reliable and compact integration of tubular batteries into electronic devices while preventing short-circuits and ensuring efficient thermal management.
Implementation Method 1
a PTC element 10 as a plate-shaped chip component... ceramic material (hereinafter also referred to as a PTC material) whose electrical resistance increase as the temperature increases
Implementation Method 2
using spot welding or reflow soldering for secure mounting
Implementation Method 3
using spot welding or reflow soldering for secure mounting
Data Source
AI summary
An externally-attached PTC element attachable to one electrode terminal of a tubular battery with electrode terminals on both end surfaces, the externally-attached PTC element including: a bottom plate made of a metal plate; a plate-shaped PTC element; and a top panel made of a metal plate, the plate-shaped PTC element and the top panel being stacked in that order above the bottom plate disposed below, the PTC element being disposed in an opposed area between the top panel and the bottom plate, the top panel projecting and extending in one direction with respect to a planar area of the bottom plate, the top panel having a distal end formed into a lead terminal shape mountable to a circuit board.