Battery Terminal Bending Lug for Low Resistance Connection
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Solution Overview
Problem
Existing battery connection methods, such as screwed-on connectors and complex plug-and-socket designs, suffer from high contact resistance, corrosion, and high fabrication and assembly costs, making them inefficient and costly for large-scale series production.
Innovation Solution
A battery design featuring a protruding terminal with an electrically conductive bending lug that can be easily bent to connect with adjacent batteries, providing a simple, cost-effective, and reliable electrical connection with low contact resistance, using a material with a suitable tension elastic limit for easy deformation and high conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screwed-on connectors are used to connect batteries, then electrical connection is achieved, but contact resistance increases and corrosion occurs over service life
Solution Approach 1:
The patent merges the connector and cable into a single integrated bending lug component that is directly formed from the battery terminal material. This eliminates the separate connector piece and multiple connection interfaces, reducing contact resistance and eliminating corrosion at connection points between different components.
Solution Approach 2:
The bending lug utilizes the mechanical flexibility of the terminal material itself to achieve connection without requiring external connectors or fastening mechanisms. The terminal serves both its electrical function and its mechanical connection function through its own deformable structure.
2Reliability
If complex plug-and-socket connectors are used, then secure electrical connection is achieved, but fabrication and assembly costs increase dramatically
Solution Approach 1:
The patent combines the cable and connector into a single bending lug that is directly formed from the terminal material. This eliminates the need for separate socket and plug components, dramatically reducing fabrication steps and assembly operations while maintaining secure electrical connection.
Solution Approach 2:
The patent extracts the complex connector assembly from the battery terminal design and replaces it with a simple bent terminal extension. This removes unnecessary components and simplifies the overall structure to only what is essential for electrical connection.
3Ease of operation
If flexible connectors are used to simplify assembly, then assembly expenditure is reduced, but connection complexity increases
Solution Approach 1:
The patent merges the flexibility function directly into the terminal material itself through the bending lug, eliminating the need for separate flexible connector components. This achieves assembly simplicity without increasing structural complexity.
Solution Approach 2:
The patent changes the mechanical parameters of the terminal material by selecting materials with appropriate flexibility and tension elastic limits. This allows the terminal to be manually bent into position without requiring complex flexible connector designs.
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 configuration allows for easy, flexible connection of batteries with low contact resistance and long service life, accommodating positioning inaccuracies and simplifying the assembly process while reducing manufacturing complexity and costs.
Implementation Method 1
the bending of the bending lug occurs right up against the outside surface... at an angle of substantially 90° with respect to the longitudinal axis of the terminal
Implementation Method 2
When the battery or the respective battery cell is discharged, chemical energy which is stored in the battery is converted into electrical energy by an electrochemical redox reaction
Implementation Method 3
at least one terminal which protrudes from an outside surface of the battery body and is electrically conductively connected to one of the battery poles
Data Source
AI summary
A battery includes a battery body and at least one terminal protruding from an outside surface of the battery body. The terminal is electrically conductively connected to one of the battery poles. The battery further includes at least one electrically conductive bending lug, which is electrically conductive, connected via the terminal to the battery pole. The bending lug has a length that is greater than a distance of the longitudinal axis of the terminal from the point of penetration through the outside surface up to a lateral edge of the outside surface.