Battery Strap Trough Design for Lead Wire Solder Stability
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Solution Overview
Problem
Conventional battery straps in battery packs often result in less than satisfactory connections with lead wires due to curling issues during soldering, leading to potential loose connections and open circuits, especially under high current conditions.
Innovation Solution
The battery strap design includes a lead wire coupling portion with a plateau having a trough to receive the lead wire and an overlap portion adjacent to the trough, ensuring stable solder connections and maintaining the lead wire's position during assembly and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery straps are used without a trough structure, then the manufacturing process is simpler, but the lead wire connection becomes unstable due to curling during soldering
Solution Approach 1:
The battery strap is segmented into distinct functional regions: a plateau portion providing a flat base, a trough portion formed by folding the strap to create a U-shaped recess, and an overlap portion where the strap folds back on itself. This segmentation allows each region to perform its specific function in preventing lead wire curling and ensuring stable connections.
Solution Approach 2:
The trough structure is pre-formed in the battery strap before the soldering process. By creating the U-shaped recess in advance, the lead wire is pre-positioned and constrained within the trough, preventing curling during the subsequent soldering operation. This preliminary structural preparation ensures connection stability without requiring additional fixtures or tools during assembly.
2Reliability
If the battery strap uses a simple flat design, then the manufacturing is easier, but the solder connection quality deteriorates under high current conditions
Solution Approach 1:
The battery strap incorporates local quality variations through its multi-region design. The plateau portion provides a flat, stable base area for solder application, the trough portion creates a confined space that holds the lead wire securely, and the overlap portion adds mechanical reinforcement. Each local region has optimized properties tailored to its specific function in the soldering process.
Solution Approach 2:
The battery strap transitions from a two-dimensional flat design to a three-dimensional structured form by folding portions of the strap to create the trough. This dimensional change creates vertical walls and a recessed space that physically constrain the lead wire, adding a new spatial dimension to the connection geometry that prevents curling and improves solder joint quality.
3Reliability
If no lead wire positioning structure is provided, then the assembly process is faster, but loose connections occur when solder material liquefies
Solution Approach 1:
The trough structure acts as a pre-prepared protective enclosure for the lead wire and solder joint. Before thermal stress occurs during soldering, the trough walls are already in place to contain and support the molten solder material. This beforehand structural preparation cushions against the potential harm of solder liquefaction, preventing loose connections without requiring additional protective measures during the assembly process.
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 provides a more stable and reliable electrical connection between the lead wire and the battery strap, enhancing current flow and preventing loose connections even when solder material liquefies during use.
Implementation Method 1
a lead wire coupling portion with a plateau having a trough to receive the lead wire
Data Source
AI summary
The present disclosure presents an electrical connector comprising a wire coupling portion, the wire coupling portion including a generally flat, plateau portion wherein the plateau portion includes a trough. The electrical connector wherein the trough is generally semi-cylindrical. The electrical connector further comprises an overlap portion that is positioned generally parallel to the plateau portion. The electrical connector wherein the overlap portion is positioned generally adjacent to an open side of the trough. The electrical connector further comprising an electrical device coupling portion at an end of the electrical connector opposite to the wire coupling portion.