Battery Pack Terminal Holder Recess for Stable Assembly Alignment
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Solution Overview
Problem
Conventional battery packs face issues with unstable electrical connections due to variations in the mounting position of the connection terminal on the terminal holder, leading to improper positioning during assembly, which affects connection stability and increases manufacturing costs.
Innovation Solution
The battery pack design includes a recess in the outer covering case opposite the terminal, allowing for the terminal holder to be stored even if the mounting position varies, with a protrusion guiding the terminal for stable exposure and an insulating plate to form the recess, ensuring proper alignment and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection terminal is made elastic to ensure stable electrical connection, then electrical connection stability is improved, but assembly positioning accuracy deteriorates due to mounting position variations
Solution Approach 1:
The recess in the holder storage space is designed to accommodate and absorb the elastic deformation of the connection terminal during assembly. This beforehand cushioning allows the terminal to be inserted at varying positions without compromising the final electrical connection stability, as the recess provides a tolerance zone for positioning variations.
Solution Approach 2:
The recess changes the spatial parameter of the holder storage space by creating a localized void or cavity. This parameter change allows the terminal holder to be positioned within a range of locations while still maintaining proper electrical connection, effectively decoupling the assembly positioning accuracy from the electrical connection stability.
2Ease of manufacture
If the mounting position of the connection terminal on the terminal holder varies, then ease of manufacture is improved, but assembly positioning accuracy deteriorates
Solution Approach 1:
The recess modifies the spatial parameters of the holder storage space, creating a tolerance zone that accommodates variations in terminal mounting position. This parameter change enables manufacturing flexibility without sacrificing assembly positioning accuracy, as the recess absorbs the positional variations.
Solution Approach 2:
The recess introduces an additional spatial dimension (depth) to the holder storage space. This dimensional change provides a buffer zone that accommodates lateral or longitudinal variations in terminal mounting position, effectively adding a degree of freedom to the assembly process.
3Manufacturing precision
If a recess is added to the holder storage space to absorb positional variations, then assembly positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The holder storage space is segmented into two functional zones: a main storage area for the terminal holder and a recessed area for absorbing positional variations. This segmentation allows the structure to handle positioning tolerances without requiring a complete redesign of the entire holder assembly.
Solution Approach 2:
The recess applies local quality modification by creating a localized void or cavity in a specific region of the holder storage space. This local structural feature provides positioning tolerance absorption without affecting the overall structural integrity or adding significant complexity to the entire device.
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
This design stabilizes electrical connections by absorbing positional variations of the terminal holder, enhancing assembly precision and reducing manufacturing defects, thus improving yield and cost-effectiveness.
Implementation Method 1
joining the terminal to the metal piece by spot welding
Data Source
AI summary
This battery pack includes: one or more secondary battery cells each including electrodes that are positive and negative; a terminal that is made of metal and is electrically connected to the electrodes of the one or more secondary battery cells; a terminal holder integrated with the terminal; and an outer covering case that stores the one or more secondary battery cells and includes a holder storage space that stores the terminal holder. The outer covering case is a part of the holder storage space and includes a recess at a position opposite the terminal.