Lead-Acid Battery Connector with Contour-Matched Welding Lug
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Solution Overview
Problem
Lead-acid rechargeable batteries experience high internal resistance and heating due to heavy currents, limiting their power output and efficiency in modern vehicles.
Innovation Solution
The battery cell connecting element features a boundary profile that matches the contour of the connector's side surface, ensuring consistent current density and reduced internal resistance, allowing for optimized material usage and reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If heavy currents flow through the battery cell connecting elements to meet high power requirements, then the power output capability is improved, but internal resistance and heating increase causing energy loss
Solution Approach 1:
The welding lug is designed with a non-uniform cross-sectional area, being wider at the connection point with the connector and gradually narrowing toward the separating wall. This local variation in geometry optimizes the current density distribution, concentrating current flow where the cross-section is larger to reduce resistive heating, while still maintaining reliable electrical connection through the separating wall.
2Loss of energy
If the welding lug has a larger cross-sectional area to reduce internal resistance, then energy loss is reduced, but the amount of material used increases
Solution Approach 1:
The welding lug features a dynamic, gradually varying cross-sectional area rather than a uniform shape. The width transitions from a maximum at the connector connection point to a minimum at the separating wall, creating an optimized current path that reduces internal resistance without requiring excessive material throughout the entire structure.
3Ease of manufacture
If the boundary of the recess has a simple shape for ease of manufacture, then manufacturing is simplified, but current density distribution becomes non-uniform increasing internal resistance
Solution Approach 1:
The boundary of the recess is designed with specific geometric parameters that match the contour of the connector's side surface. This parameter optimization ensures that when the weldinglug is formed, the resulting cross-sectional area distribution creates uniform current density, reducing internal resistance while maintaining manufacturability through defined geometric relationships.
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 reduces internal resistance and heat generation, enabling higher power emission and potentially saving material by optimizing the welding lug's composition.
Implementation Method 1
Material of the battery cell connecting element is then fused in the vicinity of the recess using hot tongs
Implementation Method 2
The tongs have welding platelets at the points where they come into contact with the battery cell connecting elements
Implementation Method 3
an electric current which flows from one plate through the connector and the welding lug through the separating wall to a further battery cell connecting element is subject to a resistance within the welding lug which is essentially independent of the current path
Data Source
AI summary
A battery, in particular a lead-acid rechargeable battery, having at least one battery cell connecting element, which has a connector, which has at least one side surface, for connection to at least one plate on a lower face of the connector, and a welding lug, which is electrically conductively connected to the connector and has a recess which is bounded by a boundary, wherein, in a section which is adjacent to the side surface of the connector, the boundary has a profile which corresponds to a contour of the side surface of the connector.