Rechargeable Battery Terminal Curvature Radius Optimization
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Solution Overview
Problem
The manufacturing process for rechargeable battery terminals, particularly plate terminals, involves costly forging and cutting processes, leading to increased costs and reduced mechanical strength and contact area with bus bars due to excessive curvature radius, resulting in unstable mechanical strength and high electrical resistance.
Innovation Solution
A rechargeable battery design featuring a terminal with a spacing part connected to the cap plate through a round part, where the curvature radius of the outer surface is less than the thickness of the connection part, increasing the contact area with the bus bar, and including a flange for enhanced mechanical strength and low electrical resistance, manufactured using a press process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the plate terminal is manufactured by a press process, then manufacturing cost is reduced and productivity is improved, but a curvature radius substantially greater than the thickness of the plate terminal is formed at the edge part, resulting in deteriorated mechanical strength and increased electrical resistance
Solution Approach 1:
The invention changes the curvature radius parameter of the round part to be less than the thickness of the connection part, which fundamentally alters the geometric parameters of the terminal structure. This parameter change enables the press process to produce terminals with both reduced manufacturing cost and improved mechanical strength, as the smaller curvature radius prevents excessive material displacement and maintains structural integrity at the edge parts
2Productivity
If the plate terminal is manufactured by a press process, then manufacturing cost is reduced and productivity is improved, but the contact area with the bus bar is reduced due to excessive curvature radius, resulting in high electrical resistance
Solution Approach 1:
By changing the curvature radius parameter to be less than the thickness of the connection part, the invention ensures that the press process produces terminals with adequate contact area. This parameter modification maintains the productivity benefits of the press process while ensuring low electrical resistance through improved contact area with the bus bar
3Strength
If the curvature radius of the round part is reduced to less than the thickness of the connection part, then mechanical strength is improved and contact area is increased, but the manufacturing process complexity increases
Solution Approach 1:
The invention sets the curvature radius parameter to be less than the thickness of the connection part, which is a straightforward parameter specification that can be directly implemented in press process tooling. This parameter change does not require additional manufacturing steps or complex processes, thereby maintaining manufacturing simplicity while achieving improved mechanical strength and contact area
Data Source
AI summary
A rechargeable battery includes an electrode assembly having a first electrode and a second electrode on either side of a separator, a case accommodating the electrode assembly, a cap plate sealing the case and electrically connected to the second electrode, a first terminal electrically connected to the first electrode and located with a terminal hole of the cap plate, and a second terminal directly connected to the cap plate, wherein the second terminal includes a spacing part spaced from the cap plate and configured to be connected to a bus bar, and a connection part connected to the spacing part through a round part and connected to the cap plate, wherein a curvature radius of an outer surface of the round part is less than a first thickness of the connection part.