Battery Connector Composite Structure for Low Resistance
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Solution Overview
Problem
Lead-acid rechargeable batteries used in commercial motor vehicles face high internal resistance due to the poor electrical conductivity of lead, leading to undesirable heating and limited power emission when high currents are required.
Innovation Solution
Incorporating a contact element laterally arranged on the welding lug to connect electrically with the connector, optimizing the material distribution for reduced electrical resistance and allowing for increased power emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connector is made entirely of lead to ensure mechanical strength and corrosion resistance, then the structural integrity is maintained, but the electrical conductivity deteriorates leading to high internal resistance
Solution Approach 1:
The connector is constructed as a composite structure combining lead (for mechanical strength and corrosion resistance) and copper (for electrical conductivity). The copper core provides low electrical resistance while the lead outer layer provides mechanical protection and corrosion resistance, resolving the contradiction between structural integrity and electrical conductivity.
Solution Approach 2:
Different regions of the connector have different material compositions optimized for their specific functions. The core region uses copper for electrical conduction where current flows, while the outer region uses lead for mechanical strength and corrosion resistance where structural support is needed, applying local quality to resolve the contradiction.
2Loss of energy
If more lead material is used in the battery cell connecting element to reduce internal resistance, then the electrical conductivity improves, but the weight and material cost increase
Solution Approach 1:
The copper-lead composite structure provides high electrical conductivity with reduced material weight. Copper has superior electrical conductivity compared to lead, so using a copper core achieves lower internal resistance without requiring excessive lead material, thus reducing overall weight while maintaining low electrical resistance.
Solution Approach 2:
The invention changes the material composition parameter from pure lead to a copper-lead composite, fundamentally altering the electrical and mechanical properties. This parameter change enables achieving low internal resistance with reduced weight by leveraging copper's superior electrical conductivity.
3Loss of energy
If the connector is designed with optimized material distribution to reduce internal resistance, then the electrical conductivity improves, but the manufacturing complexity increases
Solution Approach 1:
The connector is segmented into distinct functional zones: a copper core for electrical conduction and a lead outer layer for protection. This segmentation allows each material to be optimized for its specific function while being manufactured as an integrated component through specialized casting molds, balancing performance optimization 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 solution reduces internal resistance, minimizing heating and enabling higher power output from the battery while potentially saving material and simplifying production by modifying the casting molds.
Implementation Method 1
the welding lug is electrically connected to the connector via at least one contact element, which is arranged laterally on the welding lug and leads to the surface of the connector
Data Source
AI summary
The invention relates to a battery, comprising at least one battery cell connecting element (20), which is conductively connected to (a) a connector (28) having a cuboid-like base shape for connecting the same to at least one pole flange on a base (32) of the connector (28), and (b) a welded bracket (30), which is conductively connected to the connector (28), (c) wherein in the installed position of the battery (10) the connector (28) is disposed substantially horizontally, and the welded bracket (30) is disposed substantially vertically, and (d) wherein the connector (28) has a top (34) positioned opposite the base (32) and (c) at least one longitudinal side (36) adjoining the base (32), the welded bracket (30) being connected to the connector (28) on said side. The invention provides that the welded bracket (30) is electrically connected to the connector (28) via at least one contact element (44.1, 44.2) laterally disposed on the welded bracket (30) and leading onto the surface of the connector (28).