Battery Terminal Joint Thickness Layout for Stronger Swaging
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Solution Overview
Problem
Conventional battery terminal joining methods, such as swaging, often result in insufficient joining strength due to inadequate thickness in the joined portion, leading to potential weakness, while excessive thickness leads to over-engineering.
Innovation Solution
A battery design featuring a conductive member with a through hole and a terminal member inserted, where the joined portion has a thick and thin portion configuration to enhance joining strength without over-engineering, with the thick portion being relatively thick and the thin portion relatively thin, and processed to form a stable swaged portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the swaged portion is increased to improve joining strength, then the joining strength of the terminal member is improved, but the structure becomes over-engineered with unnecessary material excess
Solution Approach 1:
The terminal member features a non-uniform thickness distribution with a thick portion at the center of the swaged area and thinner portions at the edges. This local quality variation concentrates material where joining strength is most needed (center region under compression) while reducing material in less critical areas, thereby resolving the contradiction between achieving sufficient joining strength and avoiding material excess.
Solution Approach 2:
The invention changes the thickness parameter of the terminal member from a uniform value to a gradient distribution, with the thickest region positioned at the center of the swaged portion. This parameter optimization ensures that the maximum thickness is provided only where it contributes most to joining strength, preventing over-engineering in other regions.
2Quantity of substance
If the thickness of the swaged portion is kept thin to avoid over-engineering, then material excess is reduced, but the joining strength of the terminal member becomes insufficient
Solution Approach 1:
By concentrating the thick portion of the terminal member specifically at the center of the swaged area, the design provides maximum thickness only where it is most effective for joining strength (under compressive loading), while using thinner material at the periphery. This resolves the contradiction by ensuring sufficient strength where needed without wasting material elsewhere.
Solution Approach 2:
The invention applies the principle of partial action by providing excessive thickness (thick portion) only in the specific region where it is most needed for joining strength, rather than uniformly throughout the entire terminal member. This partial concentration of material achieves the necessary strength with overall material efficiency.
Data Source
AI summary
A battery includes: a conductive member provided with a through hole; and a terminal member inserted in the through hole and having a tip portion exposed on the conductive member. A joined portion of the tip portion of the terminal member to the conductive member is formed. The joined portion includes a thick portion at which a thickness of the terminal member is relatively thick, and a thin portion at which the thickness of the terminal member is relatively thin.