Bent Battery Connecting Lead for Low Resistance and Vibration Durability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Connecting leads in batteries require high impact resistance and low electric resistance to withstand vibrations and maintain efficient electrical connectivity, especially in large-size and high-capacity power supplies for vehicles.
Innovation Solution
A connecting lead design with a top plate portion and a leg portion bent at a specific angle, featuring a profile varying portion with varying dimensions and hardness, ensuring low electric resistance and high impact resistance through a structured configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the connecting lead is made with a simple structure, then the manufacturing cost is reduced, but the impact resistance and electrical connectivity are compromised
Solution Approach 1:
The connecting lead is divided into multiple functional segments: a top plate portion for electrical connection, a leg portion for structural support, and a profile varying portion with gradient hardness for impact absorption. This segmentation allows each part to be optimized for its specific function, achieving high impact resistance through the gradient hardness design while maintaining manufacturing feasibility through standardized processing steps.
Solution Approach 2:
The connecting lead features local quality variation through a profile varying portion where the hardness gradually changes from a first hardness value to a second hardness value. This local quality gradient allows the lead to exhibit different mechanical properties at different locations: softer regions for impact absorption and harder regions for electrical connectivity, thereby achieving high impact resistance without requiring complex overall structure.
2Reliability
If the connecting lead uses uniform material properties throughout, then the manufacturing process is simplified, but the electrical resistance and impact resistance cannot be simultaneously optimized
Solution Approach 1:
The connecting lead employs parameter changes by varying the hardness parameter along its length, creating a gradient from first hardness to second hardness in the profile varying portion. This parameter variation is achieved through controlled manufacturing processes such as selective heat treatment or material composition gradients, allowing optimization of both electrical resistance (through consistent conductive material) and impact resistance (through hardness gradient) without requiring completely different manufacturing approaches.
Data Source
AI summary
In one embodiment, a connecting lead connecting between a current collecting tab of an electrode group and an electrode terminal in a battery is provided. The connecting lead includes a top plate portion and a leg portion, a leg portion is bent relative to the top plate portion to one side in a thickness direction of the top plate portion, and a bend line at a bend position to the top plate portion is along a width direction of the top plate portion. The leg portion includes an extension portion located apart from the bend position to the top plate portion. The extension portion includes, on an outer surface, a side face relaying between a pair of main faces and facing one side in the width direction of the top plate portion. The side face is joined to the current collecting tab.