Battery Terminal Elastic Protrusion for Connection Stability
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Solution Overview
Problem
The existing rechargeable battery modules face electric connection failures due to height differences between terminals caused by process errors, leading to unstable connections and potential resistance increases or connection failures.
Innovation Solution
The design includes a terminal structure with a protrusion portion that is elastically deformable and a groove at its intersection with the base portion, allowing for stable connection with other terminals, along with an insulation member formed through insert-molding for secure installation within the cap plate, ensuring consistent terminal alignment and contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals are connected using conventional rigid structures, then manufacturing is simple, but connection stability deteriorates due to height differences from process errors
Solution Approach 1:
The terminal structure incorporates an elastically deformable protrusion portion that can dynamically adjust to height differences between terminals. The protrusion portion is designed with elastic properties allowing it to bend and compensate for dimensional variations, transforming a static rigid connection into a dynamic adaptive connection that maintains stability despite manufacturing tolerances.
Solution Approach 2:
The invention changes the physical parameter of the terminal structure by introducing elasticity to the protrusion portion. This parameter change allows the terminal to deform within elastic limits to accommodate height differences, converting a rigid structure with fixed dimensions into one with variable dimensions that can adapt to process errors.
2Manufacturing precision
If terminals are made rigid for easy manufacturing, then manufacturing precision requirements increase, but if made flexible for compensation, then manufacturing becomes more complex
Solution Approach 1:
The terminal structure performs self-adjustment through the elastic deformation of the protrusion portion. When terminals with height differences are connected, the protrusion portion automatically deforms to compensate for the discrepancy without requiring external adjustment mechanisms or complex assembly procedures, enabling the structure to self-correct manufacturing variations.
Solution Approach 2:
The elastic protrusion portion acts as a pre-designed compensation mechanism that anticipates and cushions against height differences before connection. By incorporating elastic elements in advance, the design prepares the terminal structure to absorb dimensional variations, preventing connection failures before they occur.
3Ease of operation
If insulation members are separately installed, then assembly steps increase, but if integrated through insert-molding, then manufacturing complexity increases
Solution Approach 1:
The invention merges the insulation member with the terminal structure through insert-molding, combining two previously separate components into a single integrated unit. This merging eliminates the need for separate installation steps while incorporating the molding process into the existing manufacturing flow, achieving component integration without significantly increasing overall manufacturing complexity.
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 ensures stable and reliable electrical connections between terminals, preventing connection failures and maintaining low resistance, even when terminals are at different heights, thereby enhancing the reliability and performance of rechargeable battery modules.
Implementation Method 1
a first end of the protrusion portion is fixed to the base portion and a second end of the protrusion portion is a free end. As such, the protrusion portion can be elastically deformable in a thickness direction of the protrusion portion.
Data Source
AI summary
A rechargeable battery includes an electrode assembly having a positive electrode and a negative electrode; a case housing the electrode assembly; a cap plate coupled to the case; and a terminal electrically coupled to the electrode assembly and having a base portion located on the cap plate and a protrusion portion protruding from the base portion and spaced from the cap plate.