Top Cap Assembly Mechanical Coupling for Battery Cells
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Solution Overview
Problem
The existing manufacturing process for lithium secondary battery packs is complex and prone to defects due to precise welding or soldering requirements, leading to increased costs and reduced battery capacity, as well as safety concerns from combustible materials.
Innovation Solution
A novel top cap assembly with a terminal block that uses a mechanical coupling method, such as fastening protrusions and grooves, to securely attach the protection circuit module (PCM) to the battery cell without soldering, allowing for a simplified assembly process and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding or soldering is used to couple the PCM to the top cap housing, then electrical connection is achieved, but the assembly process becomes complicated and defect rate increases
Solution Approach 1:
The patent replaces the welding/soldering process with a mechanical coupling system. The terminal block includes positioning protrusions that fit into corresponding positioning grooves on the PCB, and the top cap housing has coupling protrusions that mechanically engage with the terminal block. This mechanical coupling system eliminates the need for welding or soldering while maintaining reliable electrical connection through the connector assembly.
Solution Approach 2:
The patent introduces a terminal block as an intermediary component between the PCB and the top cap housing. The terminal block includes connectors that make electrical contact with the PCB and positioning protrusions that mechanically couple to the housing. This intermediary component simplifies the overall assembly by providing a standardized mechanical and electrical interface, eliminating the need for direct welding between the PCB and housing.
2Reliability
If welding or soldering is used to connect the PCM, then electrical connectivity is established, but the battery pack length increases reducing cell capacity
Solution Approach 1:
The patent merges the electrical connection function and mechanical support function into a single integrated terminal block assembly. The connectors are mounted on the PCB and electrically connected to the connecting parts, while the positioning protrusions on the terminal block provide mechanical coupling to the top cap housing. This integration eliminates the need for separate welding processes and associated clearanceances, thereby reducing the overall battery pack length and maximizing cell capacity.
3Reliability
If precise welding or soldering is performed, then electrical connection is achieved, but manufacturing cost increases due to increased defect rate
Solution Approach 1:
The patent replaces the complex welding/soldering process with a simple mechanical coupling system using positioning protrusions and grooves. This mechanical system is easier to manufacture with lower skill requirements, reduced equipment investment, and lower defect rates. The electrical connection is achieved through the connector assembly on the terminal block, which can be assembled using simple insertion and mechanical engagement without requiring precision welding operations.
4Reliability
If soldering processes are used, then electrical connection is established, but assembly time increases due to multiple process steps
Solution Approach 1:
The patent segments the assembly into modular components: the terminal block with mounted connectors forms one module, the positioning protrusions form another, and the top cap housing with coupling features forms a third. This segmentation allows each component to be prepared independently and then quickly assembled together through simple mechanical engagement, eliminating the time-consuming sequential steps of soldering, washing, and inspection required in traditional processes.
Data Source
AI summary
Disclosed herein is a top cap assembly mounted to a battery cell having an electrode assembly of a cathode/separator/anode structure disposed in a battery case together with an electrolyte in a sealed state, the battery case being provided at an upper end thereof with a first electrode terminal and a second electrode terminal, the top cap assembly including a protection circuit module (PCM) and an electrically insulative top cap housing mounted to the upper end of the battery cell while surrounding an outside of the PCM, wherein the PCM includes a protection circuit board (PCB) having a protection circuit formed thereon, the PCB being coupled to a mechanical coupling part of a terminal block, connecting parts connected to the first electrode terminal and the second electrode terminal, a safety element, and the terminal block mounted to the PCM, the terminal block including connectors.