Battery Pack Electrode Terminal Catch Jaws Prevent Rotation
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Solution Overview
Problem
Existing battery packs face challenges in efficiently managing charge-discharge currents and preventing bolt rotation, which can lead to electrical resistance and mechanical instability, particularly in high-output and high-capacity applications like electric vehicles.
Innovation Solution
A battery pack design featuring an electrode terminal with a bolt and plate member made of different metallic materials, where the bolt includes catch jaws, a thread portion, and a deformed portion, and the plate member has a recess and penetration hole to prevent bolt rotation, ensuring secure electrical connections and reduced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bolt is used to connect the plate member to the battery cell, then mechanical coupling strength is improved, but the bolt may rotate during tightening, leading to connection instability
Solution Approach 1:
The catch jaws are pre-formed on the bolt before assembly, positioned to engage with the plate member during the tightening process. This preliminary configuration ensures that as the bolt is tightened, the catch jaws automatically engage with the plate member's surface, preventing rotation before it can occur and ensuring stable mechanical coupling from the outset.
Solution Approach 2:
The catch jaws act as an intermediary element between the bolt and the plate member. Instead of the bolt directly contacting the plate member in a way that allows rotation, the catch jaws mediate the connection by engaging with the plate member's surface, distributing the clamping force and preventing rotational movement while maintaining strong mechanical coupling.
2Ease of manufacture
If the plate member and bolt are made of the same metallic material, then manufacturing simplicity is improved, but electrical resistance increases at the connection interface
Solution Approach 1:
The electrode terminal employs a composite material structure where the plate member is made of one metallic material and the bolt is made of a different metallic material. This composite construction optimizes the electrical connection interface by selecting materials with complementary properties, reducing electrical resistance at the connection point while maintaining manufacturing feasibility through standardized fabrication processes for each material type.
Solution Approach 2:
Different metallic materials are used at different locations of the electrode terminal assembly. The plate member uses a material optimized for its specific function, while the bolt uses a different material optimized for fastening and electrical conductivity at the connection interface. This local optimization of material properties reduces electrical resistance where it matters most while maintaining overall manufacturing simplicity.
3Stability of the object's composition
If the bolt is fully inserted through the plate member, then mechanical stability is improved, but the bolt cannot be securely prevented from rotating or loosening
Solution Approach 1:
The catch jaws are pre-formed on the bolt in a configuration that allows them to engage with the plate member during assembly. As the bolt is inserted and tightened, the catch jaws automatically position themselves to contact the plate member's surface, creating a mechanical interlock that prevents rotation or loosening while maintaining full insertion for mechanical stability.
Solution Approach 2:
The catch jaws create an asymmetric engagement between the bolt and plate member. The jaws are positioned and shaped to contact the plate member in a way that provides rotational restraint in one direction while allowing proper tightening. This asymmetric configuration prevents the bolt from rotating or loosening while maintaining secure mechanical stability through full insertion.
Data Source
AI summary
A battery pack is disclosed. In one aspect, the battery pack includes a battery cell and an electrode terminal including a plate member electrically connected to the battery cell, and a bolt passing through the plate member. The bolt includes a plurality of catch jaws disposed on opposing sides of the plate member in a length direction of the bolt and a thread portion exposed from the plate member. The plate member and the bolt include different metallic materials.