Battery Terminal Insulation Structure for Vibration Torque Reliability
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Solution Overview
Problem
Vibration-induced torque can damage the junction parts of the electrode terminal, insulating member, and sealing plate in batteries, leading to reliability issues.
Innovation Solution
Incorporating concave parts on either the electrode terminal or the insulating member, where the concave parts on the terminal are filled with the insulating member or the terminal is buried in the concave parts of the insulating member, to disperse the torque load and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode terminal is rigidly connected to the sealing plate, then electrical connection is ensured, but the junction part is vulnerable to torque-induced damage from vehicle vibration
Solution Approach 1:
The insulating member is preliminarily positioned between the electrode terminal and sealing plate to cushion against torque-induced damage before vibration occurs. This pre-positioned cushioning element absorbs and distributes the harmful forces during vehicle operation, preventing direct transmission of torque to the junction part.
Solution Approach 2:
The insulating member serves as an intermediary element between the electrode terminal and sealing plate. It mediates the mechanical stress and torque forces, providing both electrical insulation and mechanical protection to the vulnerable junction part while maintaining the electrical connection integrity.
2Reliability
If the insulating member is placed between the electrode terminal and sealing plate, then insulation is provided, but the torque load concentrates on the insulating member causing potential damage
Solution Approach 1:
The insulating member is segmented into multiple portions that wrap around different sections of the electrode terminal. This segmentation distributes the torque load across multiple contact points and structural sections, preventing concentration of stress at any single point and enhancing overall mechanical strength under torque.
Solution Approach 2:
The insulating member features locally optimized structural characteristics, including varying thickness and reinforcement at critical stress points. The local quality is enhanced where torque concentration is expected, providing targeted strength reinforcement while maintaining insulation functionality throughout.
3Strength
If a conventional rigid structure is used for the electrode terminal connection, then structural integrity is maintained, but vibration-induced torque causes damage to junction parts
Solution Approach 1:
The insulating member functions as a flexible protective shell that envelops the electrode terminal connection area. This flexible structure allows controlled deformation under torque loads, absorbing vibration-induced stresses while maintaining the structural integrity of the rigid battery components and protecting the junction part from damage.
Data Source
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AI summary
A battery preferably improved in reliability is provided. In accordance with a preferable one aspect of a battery herein disclosed, the battery comprising: an electrode body including respective electrodes of positive and negative electrodes; a battery case including an opening, and for accommodating the electrode body; a sealing plate including a terminal mounting hole, and for sealing the opening; a collector terminal electrically joined at one end thereof with any electrode of the positive and negative electrodes inside the battery case, and inserted at another end thereof through the terminal mounting hole to be exposed to outside the sealing plate; and an insulating member for establishing an insulation between at least a part of the sealing plate and the collector terminal. A plurality of concave parts are existed at the collector terminal, and the concave part is filled with the insulating member opposed to the concave part.