Inclined Terminal Surface for Battery Stack Connection
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Solution Overview
Problem
Conventional terminal connection structures for battery stacks face challenges in achieving high connection reliability between output terminals and bus bars due to position deviations caused by dimensional errors, which affect the electrical connection and overall performance of the battery stack body.
Innovation Solution
A terminal connection structure featuring an output terminal with an inclined surface and a bus bar with a parallel connection surface, where the inclined surface and connection surface are brought into surface contact to facilitate electrical connection, and welding methods like laser, fillet, or ultrasonic welding are used to secure the connection, allowing for alignment adjustments to accommodate dimensional tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional terminal connection structure with perpendicular abutment surface is used, then the structure is simple to manufacture, but connection reliability between output terminal and bus bar deteriorates due to position deviation
Solution Approach 1:
The patent applies asymmetry by changing the abutment surface from a perpendicular orientation to an inclined orientation relative to the battery lid surface. This inclined surface (with inclination angle α between 5-45 degrees) allows the bus bar to be positioned at an offset from the ideal perpendicular alignment, thereby compensating for dimensional deviations in the battery assembly while maintaining reliable electrical connection.
Solution Approach 2:
The patent employs parameter changes by modifying the geometric parameters of the connection interface. Specifically, the inclination angle α of the abutment surface is optimized within 5-45 degrees, and the offset distance between the bus bar center line and the ideal perpendicular position is controlled within 0-5mm. These parameter adjustments enable the system to accommodate dimensional variations while ensuring connection reliability.
2Reliability
If position deviation between output terminals is accommodated, then connection reliability improves, but manufacturing precision requirements worsen
Solution Approach 1:
The patent implements beforehand cushioning by designing the inclined abutment surface and offset structure in advance to absorb and compensate for position deviations. The inclined surface geometry and offset distance are pre-calculated to provide a tolerance buffer, allowing the bus bar to maintain reliable contact with the output terminal even when dimensional variations occur during manufacturing, thereby reducing the stringency of positioning precision requirements.
3Reliability
If the bus bar is pressed against the abutment surface to adjust positional relationship, then position deviation is absorbed, but connection reliability deteriorates due to insufficient contact area
Solution Approach 1:
The patent applies dimensionality change by transitioning from a point or line contact (perpendicular abutment) to a surface contact (inclined abutment). The inclined abutment surface creates a two-dimensional contact area between the bus bar and output terminal, significantly increasing the contact area compared to conventional perpendicular connections. This enhanced surface contact improves electrical connection reliability while accommodating positional offsets.
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 connection reliability between the output terminal and bus bar, improving the assembly and electrical connection of batteries in the stack while accommodating dimensional variations, thereby increasing the capacity and reliability of the battery stack body.
Implementation Method 1
welding the inclined surface and the connection surface by piercing welding performed by irradiating a surface opposite to the connection surface of the bus bar with laser
Implementation Method 2
by fillet welding performed by irradiating a peripheral edge of the connection surface with laser
Implementation Method 3
by ultrasonic welding
Data Source
AI summary
A terminal connection structure includes: an output terminal protruding from a surface of an exterior can of a battery and having an inclined surface, in a state that battery and a connection object are aligned, the inclined surface being inclined so as to be away from or close to the surface toward the connection object; and a bus bar having connection surface parallel to the inclined surface on one end side, surface contact between the connection surface and the inclined surface causing the one end side to be electrically connected to the output terminal, another end side being electrically connected to the connection object.