1. A protective circuit module for a secondary battery comprising:
a circuit board;
at least one protection control circuit element on the circuit board for preventing overcharge and over-discharge of the secondary battery;
a first conductive pad coupled to the circuit board; and
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.
2. The protective circuit module as claimed in claim 1, wherein the positive temperature coefficient device comprises:
a first conductive plate resistance welded to the first conductive pad;
a positive temperature coefficient resistance element connected to the first conductive plate; and
a second conductive plate connected to the positive temperature coefficient resistance element.
3. The protective circuit module as claimed in claim 2, wherein the first conductive plate is serial resistance welded to the first conductive pad such that at least two serial resistance welds are formed on a surface of the first conductive plate.
4. The protective circuit module as claimed in claim 2,
wherein the positive temperature coefficient resistance element is between the first conductive plate and the second conductive plate.
5. The protective circuit module as claimed in claim 2 further comprising:
a second conductive pad spaced from the first conductive pad on the circuit board;
a first conductive lead connected to the first conductive plate, the first conductive lead being connectable to a first conductive tab of the secondary battery; and
a second conductive lead connected to the second conductive pad, the second conductive lead being connectable to a second conductive tab of the secondary battery.
6. The protective circuit module as claimed in claim 1, further comprising a through hole in the circuit board such that the first conductive pad is coupled to the through hole.
7. The protective circuit module as claimed in claim 1, further comprising a through hole in the circuit board,
wherein the first conductive pad comprises:
a protrusion coupled with the through hole in the circuit board; and
a plate portion connected to the protrusion and welded to the circuit board by solder;
wherein the positive temperature coefficient device is resistance welded to the plate portion.
8. The protective circuit module as claimed in claim 7, wherein the positive temperature coefficient device comprises:
a first conductive plate resistance welded to the plate portion;
a positive temperature coefficient resistance element connected to the first conductive plate; and
a second conductive plate connected to the positive temperature coefficient resistance element.
9. The protective circuit module as claimed in claim 8, wherein the first conductive plate is direct resistance welded to the plate portion to form a direct resistance weld on the first conductive plate and a direct resistance weld on the protrusion.
10. The protective circuit module as claimed in claim 1, wherein the circuit board further comprises two longitudinal edges and has at least one circuit board protrusion on each longitudinal edge.
11. The protective circuit module of claim 2, wherein the resistance element is circular.
12. A battery pack comprising:
a secondary battery;
a first electrode tab and a second electrode tab protruding from the secondary battery;
a protective circuit module comprising:
a circuit board;
at least one protection control circuit element on the circuit board for preventing overcharge and over-discharge of the secondary battery;
a first conductive pad welded to the circuit board; and
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; and
a resin securing the protective circuit module to the secondary battery while exposing the electrode terminals of the circuit board.
13. The battery pack as claimed in claim 12, wherein the positive temperature coefficient device comprises:
a first conductive plate resistance welded to the plate portion;
a positive temperature coefficient resistance element connected to the first conductive plate; and
a second conductive plate connected to the positive temperature coefficient resistance element.
14. The battery pack as claimed in claim 12, wherein the first conductive pad comprises:
a protrusion coupled with a through hole on the circuit board; and
a plate portion connected to the protrusion and welded to the circuit board by solder;
wherein the positive temperature coefficient device is resistance welded to the plate.
15. The battery pack as claimed in claim 13, a second conductive pad spaced from the first conductive pad on the circuit board;
a first conductive lead connected to the first conductive plate, the first conductive lead being connected to a first conductive tab of the secondary battery; and
a second conductive lead connected to the second conductive pad, the second conductive lead being connected to a second conductive tab of the secondary battery.
16. The battery pack as claimed in claim 15, wherein the first conductive lead is folded to provide a first conductive lead U-shaped fold and the second conductive lead is folded to provide a second conductive lead U-shaped fold.
17. The battery pack as claimed in claim 16, wherein insulating paper is located within both the first conductive U-shaped fold and the second conductive lead U-shaped fold.
18. The battery pack as claimed in claim 12, the circuit board further comprising two longitudinal edges and having at least one circuit board protrusion on each longitudinal edge.
19. The battery pack as claimed in claim 12, wherein the positive temperature coefficient resistance element is circular.
20. The battery pack as claimed in claim 12, wherein the battery current is reduced to substantially zero when the secondary battery temperature reaches the threshold value.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A system comprising:
a supply roll of a laminate;
a mandrel for wrapping said laminate therearound;
feed rollers that spool said laminate off said supply roll onto said mandrel, said feed rollers being attached to a mounting plate by an adjustable bracket that sets an angle of said laminate with respect to said mandrel, adjacent windings of said laminate being joined to one another at overlaps thereof, wherein each winding of said laminate makes at least one complete revolution around said mandrel before said laminate advances to its next adjacent winding so as to form a gas seal at the overlaps of the adjacent windings; and
a cutting station adapted to cut cylindrical tubes formed by windings of said laminate about said mandrel.
2. The system according to claim 1, wherein adjacent windings of said laminate are joined by application of heat thereto from a heat source.
3. The system according to claim 1, further comprising a coining roller adapted to press against overlaps of adjacent windings of said laminate.
4. The system according to claim 3, wherein said coining roller is arranged to be at the same angle with respect to said mandrel as said adjustable bracket.
5. The system according to claim 1, further comprising a controller that controls and synchronizes operation of said system.
6. The system according to claim 1, wherein said cutting station is axially moveable with respect to said mandrel.
7. The system according to claim 1, wherein said cutting station comprises:
a motor that drives a drive wheel;
a cutting wheel;
a plurality of cutting blades disposed in channels formed in said cutting wheel; and
a solenoid operatively connected to said cutting wheel, wherein before cutting said cutting wheel turns together with said drive wheel and said cutting blades do not contact said laminate, and said solenoid is operative to arrest rotational movement of said cutting wheel so as to impart a centripetal force on said cutting blades, thereby thrusting them to contact and cut said laminate.