Rechargeable Battery Terminal with Contact Spring and Riveted Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rechargeable battery terminals face challenges in forming reliable and efficient electrical connections, particularly in large capacity batteries where mechanical and electrical reliability is crucial for extended use and reduced resistance.
Innovation Solution
The terminal design incorporates a current collecting terminal, a terminal plate, and contact springs made of materials like phosphor bronze or beryllium copper, which are integrally formed and riveted, with the contact springs having a predetermined region extending through the terminal plate to facilitate a permanent contact area and reduce resistance by allowing bus bars to be easily inserted, enhancing durability and electrical reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional terminal connection methods are used, then assembly is simpler, but mechanical and electrical reliability is insufficient and resistance is higher
Solution Approach 1:
The patent combines multiple connection methods into a unified terminal structure. The terminal plate integrates riveting connections (for mechanical strength) and contact spring connections (for electrical conductivity and flexibility) into a single component system, resolving the contradiction by merging structural and electrical functions in one integrated assembly that achieves both high reliability and manageable complexity
Solution Approach 2:
The terminal structure employs composite connection approaches using different materials and methods: rivets provide mechanical anchoring while contact springs provide electrical contact. This composite connection strategy uses the strengths of different materials and connection types to achieve superior overall reliability without requiring excessive complexity in any single connection method
2Reliability
If contact springs extend through the terminal plate, then resistance is reduced and electrical reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The contact springs are pre-formed with the terminal plate structure, and the terminal plate includes pre-defined through-holes and positioning features. This preliminary preparation of the terminal plate geometry simplifies the subsequent assembly process, making it easier to manufacture despite the complex three-dimensional arrangement of springs extending through the plate
Solution Approach 2:
The terminal plate serves multiple functions: it provides structural support, defines the connection geometry for both rivets and contact springs, and includes integrated through-holes that guide and position the contact springs. This multi-functionality reduces the need for separate manufacturing steps and components, easing manufacturing despite the improved electrical reliability achieved through the spring extension design
3Ease of manufacture
If terminal plate and current collecting terminal are integrally formed, then assembly is simplified, but flexibility and adaptability are reduced
Solution Approach 1:
The terminal system is segmented into distinct functional components: the integrally formed terminal plate and current collecting terminal provide structural unity and simplified assembly, while separate contact springs provide flexibility and adaptability. This segmentation allows the rigid integral structure to be combined with flexible spring elements, achieving both assembly simplicity and connection adaptability simultaneously
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 improves the mechanical and electrical reliability of rechargeable battery terminals by forming a permanent contact area using the elasticity of contact springs, reduces electric resistance, and simplifies the assembly process, thereby enhancing the performance and efficiency of rechargeable battery modules.
Implementation Method 1
forming a permanent contact area using the elasticity of contact springs
Data Source
AI summary
A terminal of a rechargeable battery having a case and an electrode assembly inside the case includes a current collecting terminal electrically connectable to the electrode assembly inside the case and for protrusion outwardly from the case, a terminal plate for positioning outside the case, the terminal plate being coupled to the current collecting terminal, and a contact spring for positioning between the outside of the case and the terminal plate, the contact spring being coupled to the current collecting terminal, the contact spring having a predetermined region extending through the terminal plate.