Battery Terminal Rivet Joint for Torque and Contact Resistance
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Solution Overview
Problem
Rechargeable batteries face issues with low torque resistance and increased electrical contact resistance due to insufficient contact area and thermal deformation at the interface between the rivet and plate terminals, leading to resistance dispersion.
Innovation Solution
The implementation of torque resistance increasing portions at the coupling interface between the coupling hole of the plate terminal and the rivet terminal, which enhances the contact area and inhibits thermal deformation, thereby increasing the coupling force and reducing electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the rivet terminal and plate terminal are connected by simple surface-to-surface contact, then the manufacturing process is simple, but the torque resistance is low and electrical contact resistance is high
Solution Approach 1:
The invention applies curvature to the contact interface by forming protrusions on the rivet terminal surface and corresponding recesses in the plate terminal coupling hole. This curved/irregular surface geometry replaces simple planar contact, increasing mechanical interlocking and torque resistance while maintaining manufacturing feasibility through standard forming processes.
Solution Approach 2:
The invention transitions from two-dimensional surface-to-surface contact to three-dimensional interlocking contact by adding protrusions and recesses. This dimensional enhancement creates multiple contact points and mechanical engagement, simultaneously improving torque resistance and electrical contact area without significantly complicating the manufacturing process.
2Ease of manufacture
If the contact area between rivet terminal and plate terminal is small, then the manufacturing is easier, but the electrical contact resistance is high
Solution Approach 1:
The protrusions and recesses create an irregular contact surface that naturally increases the effective contact area compared to flat surfaces. This curved geometry allows better electrical contact without requiring complex manufacturing processes, as the protrusions can be formed through standard stamping or extrusion techniques.
Solution Approach 2:
By adding vertical dimension through protrusions and recesses, the contact area is effectively increased from a simple planar interface to a multi-level interlocking structure. This dimensional enhancement improves electrical contact resistance while maintaining manufacturing simplicity through conventional forming processes.
3Device complexity
If the contact area between rivet terminal and plate terminal is insufficient, then the device structure is simpler, but thermal deformation cannot be inhibited
Solution Approach 1:
The curved surfaces of the protrusions and recesses provide better thermal contact and distribution. This geometry increases the effective thermal contact area, allowing heat to be more evenly distributed across the joint, thereby reducing thermal deformation without significantly increasing structural complexity.
Solution Approach 2:
The three-dimensional interlocking structure with protrusions and recesses provides multiple contact points that distribute thermal stress more effectively. This dimensional enhancement creates a more robust thermal path while maintaining relatively simple device structure, as the features are integrated into the existing terminal components.
4Ease of operation
If the coupling force between rivet terminal and plate terminal is weak, then the assembly is easier, but the electrical resistance dispersion is high
Solution Approach 1:
The curved contact surfaces of the protrusions and recesses create mechanical interlocking that increases coupling force. This geometric feature provides natural mechanical engagement that strengthens the joint without complicating the assembly process, as the interlocking features guide proper alignment during assembly.
Solution Approach 2:
By transitioning from planar to three-dimensional contact with protrusions and recesses, the coupling force is enhanced through mechanical interlocking. This dimensional enhancement provides better electrical contact and reduced resistance dispersion while maintaining ease of assembly, as the interlocking features self-align during the assembly process.
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 design increases torque resistance and reduces electrical contact resistance and thermal deformation, resulting in decreased electrical resistance dispersion during normal operation.
Implementation Method 1
Since the torque resistance increasing portions increase the contact area between the plate terminal and the rivet terminal which are coupled to each other, it is possible to reduce electrical contact resistance
Implementation Method 2
since the torque resistance increasing portions increase the contact area between the plate terminal and the rivet terminal, thermal deformation caused by a thermal shock is inhibited
Data Source
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AI summary
A rechargeable battery according to an exemplary embodiment of the present invention includes: an electrode assembly which is charged with an electric current and discharged; a casing which accommodates therein the electrode assembly; a cap plate which is coupled to an opening of the casing; and an electrode terminal which is electrically connected to the electrode assembly and installed in a terminal hole of the cap plate, in which the electrode terminal includes: a plate terminal which is disposed outside the cap plate and has a coupling hole; and a rivet terminal which is installed in the terminal hole and coupled to the coupling hole, and the plate terminal and the rivet terminal include torque resistance increasing portions which are formed at a coupling interface between the coupling hole and the rivet terminal and increase torque resistive force of the plate terminal with respect to a z-axis of the rivet terminal.