Rechargeable Battery Eccentric Hexagonal Terminal Connection
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Solution Overview
Problem
High-capacity rechargeable batteries face issues with relative rotation of structures and electrode terminals, leading to potential mechanical failure and electrical insulation breakdown under torque, especially in high-current applications.
Innovation Solution
The battery design incorporates eccentric connection portions between the cap plate, insulators, and electrode terminal, utilizing protrusions and grooves to prevent rotation and ensure secure, torque-resistant connections, while maintaining electrical insulation through strategically placed gaskets and flanges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection methods are used for electrode terminals, then assembly is simple, but relative rotation occurs under torque leading to mechanical failure and insulation breakdown
Solution Approach 1:
The patent employs asymmetric connection structures including a hexagonal protrusion on the electrode terminal that mates with a corresponding hexagonal groove in the cap plate. This asymmetric geometry prevents relative rotation between components under torque, providing mechanical stability and preventing insulation breakdown while maintaining assembly simplicity through direct engagement.
2Reliability
If resin-based connection methods are used, then rotation is prevented, but manufacturing costs increase
Solution Approach 1:
The patent replaces resin-based mechanical bonding with a direct mechanical engagement system consisting of a hexagonal protrusion on the electrode terminal fitting into a hexagonal groove in the cap plate. This mechanical interlocking system prevents rotation without requiring additional resin materials or complex bonding processes, thereby reducing manufacturing costs while maintaining effective rotation prevention.
3Reliability
If eccentric connection portions are used, then rotation is prevented and mechanical stability is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses asymmetric hexagonal geometry for the connection portions where a hexagonal protrusion on the electrode terminal mates with a hexagonal groove in the cap plate. The eccentric positioning of these asymmetric features provides inherent rotational stability under torque while the geometric constraints of the hexagonal shape tolerate reasonable manufacturing variations, balancing torque resistance with manufacturability.
Data Source
AI summary
A battery includes a case housing an electrode assembly, the case having an opening for receiving the electrode assembly, a cap plate combined with the opening so as to close the case, a first insulator on an outer surface of the cap plate, an electrode terminal electrically connected to the electrode assembly, the electrode terminal extending through a first terminal hole in the cap plate and a second terminal hole in the first insulator, a first connection portion that mates the cap plate to the first insulator so as to oppose rotation of the first insulator relative to the cap plate, the first connection portion being eccentric with respect to a central line of the first terminal hole, and a second connection portion that mates the first insulator to the electrode terminal so as to oppose rotation of the electrode terminal relative to the first insulator.