AA Li-Ion Battery Assembly Using Elastic Spring Contacts
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Solution Overview
Problem
The existing preparation methods for No. 5 lithium-ion batteries face challenges in process control, production efficiency, and product quality, leading to safety concerns and difficulties in large-scale production due to the use of soft-package cores and specialized chargers.
Innovation Solution
A standardized preparation process involving the selection and stamping of steel materials for the battery shell, precise bending of spring sheets to form electrical connections, assembly with a PCB board, and final packaging with insulating films to ensure mechanical protection, structural integrity, and stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a soft-package core is used with welding and step-down circuit insertion, then the battery can be assembled, but the process becomes complex and large-scale mass production becomes challenging
Solution Approach 1:
The patent divides the battery structure into modular components: a steel shell housing, a PCB board with integrated spring sheets, and a battery cell. This segmentation allows each component to be manufactured and assembled independently, simplifying the overall manufacturing process and enabling mass production while eliminating the need for complex welding operations.
Solution Approach 2:
The spring sheets serve multiple functions simultaneously: they provide electrical connection between the battery cell and PCB, offer mechanical support and positioning, and enable elastic contact for reliable connectivity. This multi-functionality reduces the number of separate components needed, simplifying the assembly process while maintaining manufacturing scalability.
2Productivity
If traditional preparation methods are used, then assembly can be completed, but production efficiency is low and product quality is inconsistent
Solution Approach 1:
The spring sheets are pre-bent to the required shape and dimensions before assembly. The PCB board is pre-assembled with the spring sheets attached, creating a pre-integrated unit that is then simply inserted into the steel shell. This preliminary preparation of components significantly improves production efficiency and ensures consistent quality by allowing precise control during the pre-assembly stage.
Solution Approach 2:
The patent replaces traditional welding operations with a mechanical elastic contact system using spring sheets. This substitution eliminates the complexity and quality variability associated with welding processes, while enabling faster, more consistent assembly suitable for mass production. The elastic mechanical connection provides reliable electrical contact without the need for thermal processing.
3Reliability
If spring sheets are bent for elastic contact, then stable electrical connection is achieved, but precise control of bending parameters is required
Solution Approach 1:
The spring sheets are designed with inherent elasticity, allowing them to dynamically adapt to slight variations in assembly positioning and battery cell dimensions. This dynamic capability ensures stable electrical contact is maintained even with minor dimensional tolerances, reducing the stringency of bending parameter control requirements while preserving connection reliability.
Solution Approach 2:
The patent optimizes the material properties and geometric parameters of the spring sheets (such as thickness, width, and initial curvature) to achieve the desired elastic contact force. By carefully selecting these parameters during the design stage, the system achieves reliable electrical connection with manageable manufacturing tolerances, balancing connection stability with manufacturing feasibility.
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
The method ensures the quality and performance of lithium-ion batteries meet design requirements, providing a safe and reliable finished product suitable for practical applications by ensuring accurate electrical connections and environmental protection.
Implementation Method 1
bending a negative spring sheet on a side of the PCB board towards a direction close to the battery cell, so that the negative spring sheet is in elastic contact with the upper steel shell
Data Source
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AI summary
The present application relates to a preparation method, apparatus, device and medium for a No. 5 lithium-ion battery. The method includes: preparing a battery cell based on a preparation process of the battery cell; selecting a steel material for preparing the battery and stamping it to obtain an upper steel shell of the battery; acquiring and determining bending parameters of the spring sheet based on user requirements and attribute parameters of the spring sheet; assembling a PCB board and the upper steel shell of the battery based on the bending parameters of the spring sheet, bending a negative spring sheet on a side of the PCB board downwards, so that the negative spring sheet is in elastic contact with the upper steel shell, and bending a positive spring sheet at a bottom of the PCB board downwards, so that the positive spring plate is in elastic contact with a top of the battery cell, thus obtaining a complete step-down charging terminal; fitting the complete step-down charging terminal onto the battery cell to obtain a semi-finished product of the battery; and fixing the semi-finished product of the battery by roller pressing along a groove of the battery cell, and covering an insulating film on a outside of the semi-finished product after being fixed roller pressing to obtain a finished product of the battery. The present application has an effect of improving a safety of lithium-ion batteries.