Riveted Battery Cover Terminal Joint With Stepped-Hole Interlock
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Solution Overview
Problem
The existing connection method between the terminal and the riveting block in battery covers is prone to instability and unreliability due to extrusion, leading to poor connection strength and a high risk of cold joints and aging peeling.
Innovation Solution
A riveted battery cover design featuring a riveting block with coaxially disposed step holes, where the terminal passes through and forms a protrusion in the second step hole, enhancing the connection strength and reliability by laser welding the protrusion to the block, and incorporating a sealing member for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal is securely connected to the riveting block by extrusion, then the assembly process is simple, but the connection strength and reliability are poor
Solution Approach 1:
The riveting block is divided into two coaxially disposed step holes with different diameters. The first step hole has a smaller diameter for initial insertion, while the second step hole has a larger diameter for the final connection. This segmentation allows the terminal to be inserted through the first hole and then expanded or formed within the second hole to create a secure mechanical interlock, thereby improving connection strength while maintaining assembly simplicity.
Solution Approach 2:
The connection mechanism transitions from simple linear extrusion to a multi-dimensional engagement. The stepped configuration of the holes creates radial and axial dimensions of connection, where the terminal can be inserted axially through the first hole and then engage radially with the walls of the second hole, providing multi-directional mechanical interlocking that significantly enhances connection strength.
2Ease of manufacture
If the terminal is securely connected to the riveting block by extrusion, then the assembly process is simple, but the reliability is poor due to cold joints and aging peeling
Solution Approach 1:
The riveting block is divided into two coaxially disposed step holes with different diameters. The first step hole has a smaller diameter for initial insertion, while the second step hole has a larger diameter for the final connection. This segmentation allows the terminal to be inserted through the first hole and then expanded or formed within the second hole to create a secure mechanical interlock, thereby improving connection strength while maintaining assembly simplicity.
Solution Approach 2:
The connection mechanism transitions from simple linear extrusion to a multi-dimensional engagement. The stepped configuration of the holes creates radial and axial dimensions of connection, where the terminal can be inserted axially through the first hole and then engage radially with the walls of the second hole, providing multi-directional mechanical interlocking that significantly enhances connection strength.
3Strength
If laser welding is adopted at the riveting position of the terminal and the riveting block, then the connection strength is improved, but the device complexity increases
Solution Approach 1:
The riveting block is pre-formed with two coaxially disposed step holes of different diameters before the assembly process. This preliminary preparation of the hole structure allows the terminal to be inserted and mechanically engaged without requiring additional welding operations. The mechanical interlock created by the stepped holes provides sufficient connection strength, eliminating the need for laser welding and thereby reducing process complexity while maintaining connection strength.
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 significantly increases the connection strength and reliability between the terminal and the riveting block, reduces the risk of cold joints and peeling, and ensures a secure, sealed assembly, thereby improving the overall stability and yield of the battery cover.
Implementation Method 1
laser welding is adopted at the riveting position of the terminal and the riveting block
Implementation Method 2
the bottom insulator is securely connected to the top cover by ultrasonic welding
Data Source
AI summary
Provided is a riveted battery cover which relates to the technical field of battery cover assembly. The riveted battery cover includes a terminal and includes a riveting block, an upper plastic insulator, a top cover, and a bottom insulator which are successively stacked. A first step hole and a second step hole are coaxially disposed in the riveting block. A stamped end of the terminal successively passes through the bottom insulator, the top cover, the upper plastic insulator, the first step hole, and the second step hole. A part of the stamped end of the terminal protruding from the first step hole is stamped to form a protrusion located in the second step hole.