Battery Test Probe Elastic Contact for Stable Current
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Solution Overview
Problem
Conventional charge and discharge test probes for secondary batteries experience unstable contact with electrode terminals, leading to difficulties in applying voltage and current due to oblique contact, which results in contact failures and inconsistent testing results.
Innovation Solution
The design incorporates a head with an elastic contact member, such as a canted coil spring, leaf spring, or helical elastic member, that protrudes beyond the probe tip to ensure surface contact with the electrode terminal, increasing the contact area and allowing for smooth and continuous current application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional test probe with planar contact portions is used, then the structure is simple, but the contact area with the electrode terminal is small causing unstable contact
Solution Approach 1:
The contact portions are changed from planar surfaces to spherical shapes. This curvature allows the spherical contact portions to naturally conform to the electrode terminal surface, increasing the actual contact area and improving contact stability during testing.
Solution Approach 2:
The contact portions are designed with elastic properties that allow them to deform under load. This elastic deformation enables the contact portions to adapt to surface variations on the electrode terminal, maintaining stable electrical contact throughout the testing process.
2Reliability
If the contact portions are made rigid with predetermined size, then the manufacturing is easy, but the contact becomes oblique leading to contact failure
Solution Approach 1:
The contact portions are designed as elastic elements that can dynamically adjust their shape and position in response to applied forces and surface irregularities. This dynamic capability allows the contact portions to maintain optimal contact orientation and prevent oblique contact failures.
Solution Approach 2:
The elastic contact portions are pre-configured with inherent compliance that allows them to automatically adjust to the electrode terminal surface before full contact is established. This preliminary adaptation prevents oblique contact and ensures reliable electrical connection from the moment of contact.
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 configuration enhances the reliability of current application to the electrode terminal, compensates for contact errors, and ensures stable testing by maintaining contact through elastic deformation and recovery, thereby improving the accuracy of charge and discharge tests.
Implementation Method 1
the elastic contact member may preferably be elastically deformed by compressive force when coming into contact with an electrode terminal of a secondary battery and is recovered when the compressive force is removed
Data Source
AI summary
A charge and discharge test probe for a secondary battery includes: an inner plunger moved up and down by elastic force of a spring; a head having a central through hole through which the inner plunger passes to protrude from an upper end of the head; and a first conductive elastic member mounted to the head.