Battery Tab Terminal Coupling With Wedge Clamping for Low Resistance
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Solution Overview
Problem
Existing connections between tab electric terminals in battery cells face issues with mechanical stability and high contact resistance, particularly under vibrations, and are often irreversible, hindering maintenance and efficiency in electric vehicles.
Innovation Solution
A coupling device with jaws and wedge surfaces that clamp tab terminals together, converting pressure into direct contact pressure across the entire terminal surface, ensuring stability and low resistance, and allowing for reversible connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw terminals are used with nuts and busbars, then electrical connection is achieved, but contact resistance increases and mechanical stability decreases under vibrations
Solution Approach 1:
The invention extracts and eliminates the intermediate components (nuts, multiple contact surfaces) from the traditional screw terminal connection. By directly clamping the tab terminals between two jaws, the connection path is simplified, removing the sources of high contact resistance and mechanical instability while maintaining electrical connection functionality.
Solution Approach 2:
Instead of using a screw-nut threaded connection where the fastening element penetrates through the terminal, the invention inverts the approach by clamping the terminal between two flat jaws. This inversion creates a larger contact surface area and more stable mechanical connection that resists vibrations better.
2Strength
If crimping is used to connect tab terminals, then mechanical connection is achieved, but contact quality is poor and vibration resistance is limited
Solution Approach 1:
The invention transitions from the one-dimensional penetration approach of crimping (where a single point or narrow area contacts the terminal) to a two-dimensional clamping approach. The jaws provide a broad contact surface area across the terminal width, distributing the mechanical force and electrical current over a larger area, thereby reducing contact resistance while maintaining strong mechanical connection.
3Loss of energy
If laser welding is used to connect tab terminals to busbar, then low resistance connection is achieved at welding areas, but mechanical stability is limited and the process is irreversible
Solution Approach 1:
The coupling device serves multiple functions simultaneously: it provides mechanical clamping for stability, creates low contact resistance through broad jaw-terminal contact, and enables reversible connection unlike welding. This multi-functionality resolves the contradiction by achieving low resistance without sacrificing mechanical stability or reversibility.
Solution Approach 2:
The invention introduces dynamic adjustability through the screw mechanism that allows the jaws to be tightened or loosened. This dynamic capability enables optimal contact pressure to be applied for low resistance while maintaining mechanical stability, and also allows for reversible disconnection, overcoming the limitations of static laser welding.
4Strength
If direct welding between tab terminals is used, then mechanical deformation connection is achieved, but contact quality is poor and vibration resistance is limited
Solution Approach 1:
The invention transitions from the one-dimensional penetration approach of crimping (where a single point or narrow area contacts the terminal) to a two-dimensional clamping approach. The jaws provide a broad contact surface area across the terminal width, distributing the mechanical force and electrical current over a larger area, thereby reducing contact resistance while maintaining strong mechanical connection.
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 coupling device provides a mechanically stable and low-resistance connection that maintains contact pressure even under vibrations, ensuring efficient energy transfer and allowing for reversible maintenance of tab terminals.
Implementation Method 1
One or more wedge surfaces are present in the coupling device, arranged so as to convert a pressure in the first direction, developed by the clamping of the pair of jaws, into a pressure in the second direction
Data Source
AI summary
The present disclosure relates to a coupling device for coupling two or more tab electric terminals of distinct battery cells. A pair of U-shaped jaws retains the terminals therebetween with the electrical contact surfaces facing each other. A clamping element is configured to clamp the jaws towards each other in the first direction. During the clamping, an inclined wedge surface converts the pressure in the first direction to a pressure on the terminals in a second direction, so as to establish a reliable electrical contact between the terminals, direct or with the interposition of a spacing block. Wedge surfaces can be provided laterally, for example in the arms of the jaws, or between distinct bodies forming a spacing block between the terminals.