Battery Module Terminals with Asymmetric Differentiation for Vibration Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rechargeable battery modules face issues with vibration and shock, leading to contact resistance and reduced lifespan due to loose connections and difficulty in differentiating positive and negative terminals during assembly.
Innovation Solution
The use of terminals with differentiation portions such as indentations and protrusions, and connection members with verification portions that fit these features, fixed by welding to enhance assembly efficiency and prevent contact resistance, ensuring stable connections and improved output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection members are fixed to terminals using conventional methods, then assembly is simpler, but connections become loose under vibration and shock causing contact resistance
Solution Approach 1:
The terminal structure employs asymmetric differentiation portions (protrusions and indentations) that create a non-symmetric fit with verification portions on connection members. This asymmetric design ensures proper orientation and secure mechanical interlocking, preventing loose connections under vibration and shock while maintaining reliable electrical contact without requiring complex assembly procedures
Solution Approach 2:
The connection member's verification portions are designed to fit into and nest within the differentiation portions of terminals. This nesting arrangement creates a mechanically interlocked structure where the connection member is securely retained on the terminal, preventing loosening due to external vibrations and shocks while maintaining simple assembly through straightforward insertion and welding
2Ease of operation
If terminals lack differentiation features, then manufacturing is simpler, but positive and negative terminals cannot be distinguished during assembly
Solution Approach 1:
Differentiation portions (protrusions or indentations) are asymmetrically positioned on terminals to provide visual and tactile distinction between positive and negative terminals. This asymmetric feature enables easy identification during assembly without requiring complex marking systems or additional components, maintaining manufacturing simplicity while improving operational ease
Solution Approach 2:
The terminal structure incorporates localized differentiation portions at specific locations on the terminal surface. These local features (protrusions or indentations) provide terminal identification without requiring modification of the entire terminal structure, thus maintaining manufacturing simplicity while enabling easy distinction between positive and negative terminals during assembly
3Duration of action of stationary object
If connection members are not securely fixed, then assembly is easier, but vibration and shock cause loose connections and reduced lifespan
Solution Approach 1:
The terminal and connection member are pre-designed with complementary differentiation and verification portions that create a mechanical interlocking structure before final welding. This preliminary mechanical engagement ensures proper alignment and secure positioning, preventing loose connections under vibration and shock, while maintaining assembly ease through straightforward insertion followed by welding
Solution Approach 2:
The asymmetric differentiation portions on terminals and corresponding verification portions on connection members create a mechanically interlocked structure that resists loosening under vibration and shock. This asymmetric design ensures secure fixation that extends battery lifespan while maintaining relatively simple assembly procedures through straightforward insertion and welding
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 improves the assembly process, reduces contact resistance, and extends the lifespan of rechargeable batteries by securely fixing connection members to terminals, enhancing the overall performance and reliability of battery modules.
Implementation Method 1
a rivet that fixes the first terminal or the second terminal to the cap plate
Implementation Method 2
The first terminal and the second terminal of the adjacent rechargeable batteries are joined to the connection member by welding
Data Source
AI summary
A battery module according to the present invention includes rechargeable batteries that include a first terminal and a second terminal which protrude outward, the first terminal including differentiation portions formed of an indentation or a protruding portion to differentiate the first terminal from the second terminal; and connection members that electrically connect the rechargeable batteries, fixed to the first and second terminals of adjacent rechargeable batteries, including verification portions which fit the differentiation portions so as to improve assemblability and minimize contact resistance.