Elastic Conductive Elements for Battery Lead Connection

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Solution Overview

Problem

Conventional multiple-cell lithium-ion batteries face difficulties in assembly due to complex structures and adverse effects on cell performance from the soldering process used for connecting positive and negative leads.

Innovation Solution

The use of electrically conductive elastic elements, made from copper alloy, to connect positive and negative leads in series and/or parallel within a battery case, eliminating the need for soldering and simplifying assembly by resiliently abutting against the leads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering is used to connect positive and negative leads of cells, then electrical connectivity is achieved, but cell performance deteriorates due to high temperature exposure

Engineering Contradiction:

Improveelectrical connectivityVSAvoidhigh temperature exposure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the thermal field (soldering) with a mechanical field system using elastic conductive elements. These elements physically press against the positive and negative leads to establish electrical connections without heat, thereby eliminating thermal damage to the cell performance while maintaining reliable electrical connectivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces elastic conductive elements as intermediary components between the positive and negative leads. These intermediaries establish electrical connections through mechanical contact rather than thermal bonding, serving as a bridge that avoids direct high-temperature exposure to the cell components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If mounting board is used to connect leads, then soldering is eliminated, but device complexity increases

Engineering Contradiction:

Improvesoldering eliminationVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the mounting board component from the battery structure. By removing this intermediate component, the design achieves lead connection without soldering while simultaneously reducing structural complexity, as the elastic conductive elements directly connect leads without requiring a separate mounting substrate.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the functions of electrical connection and mechanical support into a single integrated elastic conductive element. This eliminates the need for separate mounting boards and connection components, thereby reducing device complexity while achieving the goal of eliminating soldering.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If soldering procedure is used, then electrical connection is established, but assembly difficulty increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidassembly difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the complex thermal process of soldering with a simple mechanical insertion process. The elastic conductive elements are designed to be easily inserted between leads and automatically establish electrical connections through their resilient contact, dramatically simplifying the assembly process while maintaining reliable electrical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The elastic conductive elements possess self-adjusting properties where their elastic deformation automatically ensures reliable electrical contact upon insertion. This self-service mechanism eliminates the need for precise alignment or additional fastening steps, making assembly straightforward while guaranteeing electrical connection reliability.

Inventive Principle:

Principle #25Self-service

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 solution prevents adverse temperature effects on cell performance, simplifies the assembly process, and maintains electrical connectivity without soldering, enhancing the ease and efficiency of battery construction.

Implementation Method 1

Each elastic element includes two contacting portions resiliently abutting against the two adjacent positive leads and/or negative leads

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS8153294B2Multiple-cell battery

Publication Date: 2012.04.10 DONGGUAN AMPEREX TECH

AI summary

A multiple-cell battery includes a battery case and a number of cells positioned in the battery case. Each of the cells includes a positive lead and a negative lead. A number of electrically conductive elastic elements are correspondingly seated between every two adjacent positive leads and/or negative leads. The elastic elements each include at least two contacting portions resiliently abutting against the two adjacent positive leads and/or negative leads, so as to connect the cells in series and/or in parallel.