Convex-Concave Battery Terminal Interlock for Reliable Connection
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Solution Overview
Problem
The existing battery pack manufacturing process is complex due to the need for precise alignment and fastening of electrode terminals, leading to potential electrical connection releases between adjacent battery cells and external circuits.
Innovation Solution
The energy storage apparatus features a design with convex and concave connecting portions on adjacent external terminals, which are fitted together to prevent separation and ensure reliable electrical connections, using a method that involves pressing these portions between molds to form a secure fit, thereby simplifying the assembly process and enhancing connection stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fastening members are inserted into coupling holes to connect adjacent battery cells, then electrical connection between battery cells is achieved, but the work becomes complicated and connection reliability deteriorates due to misalignment and improper fastening
Solution Approach 1:
The invention applies asymmetry by providing a convex portion on one electrode terminal and a corresponding concave portion on the adjacent electrode terminal. This asymmetric design eliminates the need for alignment holes and fastening members, as the convex-concave interface inherently guides and secures the connection. The asymmetric shapes ensure proper orientation and prevent misalignment issues that plague symmetric fastening systems.
Solution Approach 2:
The invention extracts and eliminates the fastening members (such as rivets and bolts) from the connection system. By removing these separate fastening components and replacing them with an integrated convex-concave geometry, the design simplifies the assembly process and reduces the number of parts required, while maintaining or improving connection reliability.
2Strength
If multiple fastening members are used to secure electrode terminals, then connection strength is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The invention merges the functions of multiple fastening members into a single integrated geometric feature. The convex portion with its enlarged cross-section inherently provides both alignment guidance and mechanical securing functions that previously required separate fastening components. This consolidation maintains connection strength while dramatically improving manufacturing efficiency by eliminating multiple fastening operations.
Solution Approach 2:
The convex portion is pre-formed with an enlarged cross-sectional area at its distal end, which preliminarily prepares the connection interface for secure engagement. This preliminary geometric configuration ensures that when the electrode terminals are brought together, the connection is automatically secured without requiring additional fastening steps, thereby improving productivity.
3Reliability
If coupling holes are provided in electrode terminals for fastening, then electrical connection is achieved, but alignment precision becomes difficult to maintain and connection release may occur
Solution Approach 1:
The asymmetric convex-concave design inherently guides alignment through its geometric configuration. The convex portion fits into the concave portion in a single correct orientation, eliminating the need for precise alignment of holes. This design makes the connection process tolerant of manufacturing variations while ensuring stable and reliable electrical connection.
Solution Approach 2:
Instead of providing holes that require precise alignment and insertion of fastening members, the invention inverts the approach by providing protruding convex portions that actively seek and engage with corresponding concave portions. This inversion transforms the alignment problem into a self-guiding engagement process, improving both manufacturing precision and connection stability.
Data Source
AI summary
An energy storage apparatus including: a plurality of energy storage devices each including a pair of external terminals, wherein one of two adjacent energy storage devices among the plurality of energy storage devices includes a connecting portion having at least a convex part at one of the pair of external terminals, the other of the two adjacent energy storage devices includes a connecting portion having at least a concave part at the other of the pair of external terminals, and the convex part is fitted into the concave part.