Battery Adapter Strip Bracket Structure for Stable Welding
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Solution Overview
Problem
The adapter strip in existing battery designs is prone to deformation during welding, leading to welding deficiencies and impaired weld quality due to its suspended connection to the electrode terminal, which affects the reliability and efficiency of the connection.
Innovation Solution
A battery unit design featuring an adapter strip assembly supported by a bracket, which is molded onto the adapter strip through injection molding, allowing for reliable and efficient connection to the electrode terminal, with detachable and snap-fit connections for ease of assembly and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the adapter strip is connected to the lower part of the tab, then the adapter strip can be suspended to achieve a simple structure, but the adapter strip deforms downward under gravity and thrust force during welding, resulting in welding deficiency and impaired weld quality
Solution Approach 1:
A supporting stand is introduced as an intermediary component between the adapter strip and the battery cell. The supporting stand includes a support plate with a through hole that receives the adapter strip, and a support column extending downward to contact the battery cell. This intermediary structure prevents direct suspension of the adapter strip, eliminating deformation during welding while maintaining structural simplicity.
Solution Approach 2:
The supporting stand extends in the vertical dimension (downward from the adapter strip into the battery cell), transforming the problem from a two-dimensional planar connection to a three-dimensional spatial structure. This additional vertical dimension provides mechanical support that prevents downward deformation during welding, resolving the contradiction between structural simplicity and weld quality.
2Ease of manufacture
If the adapter strip is suspended without support, then the structure remains simple and easy to manufacture, but the adapter strip is prone to deformation under gravity and thrust force, severely impairing welding quality
Solution Approach 1:
The supporting stand serves as a mediator that maintains the adapter strip in a stable horizontal position during welding. The support plate with through hole and support column structure provides precise positioning and support, ensuring the adapter strip does not deform under gravity or thrust force, thereby achieving high welding precision while keeping the manufacturing process simple.
3Productivity
If the adapter strip assembly uses a bracket supported structure, then the connection reliability and production efficiency are improved, but the device complexity and assembly complexity increase
Solution Approach 1:
The supporting stand is integrated with the battery cell structure, where the support column extends downward to contact the battery cell directly. This merging of the supporting structure with the existing battery cell reduces the need for separate, complex assembly components, thereby improving production efficiency while minimizing the increase in device complexity.
Solution Approach 2:
The supporting stand is divided into distinct functional segments: the support plate with through hole for receiving the adapter strip, and the support column for providing vertical support. This segmentation allows for simple, modular manufacturing and assembly, improving productivity while keeping the overall structure manageable and not excessively complex.
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 solution enhances the reliability and efficiency of the adapter strip connection, improving the production efficiency of the battery unit by ensuring stable mounting and reducing assembly complexity while allowing for easy repair and replacement.
Implementation Method 1
the first bracket is molded by an injection molding process in which the first adapter strip is an insertion piece
Data Source
AI summary
A battery unit, a battery module, and an electrical device are disclosed. The battery unit includes: a housing, where the housing comprises a first electrode terminal and a second electrode terminal; at least one battery cell, where the battery cell includes a first electrode plate and a second electrode plate, and the second electrode terminal is connected to the second electrode plate; and an adapter strip assembly, where the adapter strip assembly is sandwiched between the housing and the battery cell and includes a first adapter strip and a first bracket, and the first adapter strip is supported on the first bracket and connected to the first electrode terminal and the first electrode plate.