Insulated Battery Test Pin Structure to Prevent Flange Shorting

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Solution Overview

Problem

Secondary battery charge and discharge tests face a high risk of short circuits due to the flange from welding and cutting processes potentially contacting the charge and discharge pin, especially when testing high currents with increased pin size and thinner cell thickness.

Innovation Solution

A secondary battery charge and discharge pin with an insulating member covering at least part of the head, positioned near the flange, to prevent electrical contact and a probe featuring an insulating internal plunger and external plunger to ensure electrical insulation during testing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the charge and discharge pin size is increased to test high currents, then the current testing capability is improved, but the risk of short circuit with the flange increases

Engineering Contradiction:

Improvecurrent testing capabilityVSAvoidshort circuit risk

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

An insulating member is introduced as an intermediary between the charge and discharge pin and the battery case flange. This insulating member prevents direct electrical contact between the pin and the conductive flange, thereby eliminating the short circuit risk while allowing the pin to maintain its larger size for high current testing capabilities.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If the cell thickness is reduced to achieve higher energy density, then the energy density is improved, but the risk of short circuit between flange and pin increases

Engineering Contradiction:

Improveenergy densityVSAvoidshort circuit risk

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The insulating member serves as a mediator that prevents electrical contact between the pin and flange in thin-cell configurations. By introducing this insulating barrier, the design enables reduced cell thickness for higher energy density while maintaining electrical isolation to prevent short circuits.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Power

If the pin is made larger for high current testing, then the current handling capacity is improved, but the proximity to the flange increases short circuit risk

Engineering Contradiction:

Improvecurrent handling capacityVSAvoidshort circuit hazard

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The insulating member acts as a protective intermediary that allows the pin to be larger for high current handling while preventing the harmful short circuit effect. The insulating member is positioned between the pin and flange to block electrical contact, thus enabling large pin dimensions without increasing short circuit risk.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4679667A1Secondary battery charge and discharge pin and probe for secondary battery charge and discharge test including the same

Publication Date: 2026.01.14 SAMSUNG SDI CO LTD

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AI summary

The present disclosure provides a secondary battery charge and discharge pin (120, 220, 420, 600, 800, 1020, 1312) and a probe for a secondary battery charge and discharge test including the same. A secondary battery charge and discharge pin (120, 220, 420, 600, 800, 1020, 1312) according to the present disclosure includes a head (122, 222, 422, 1100, 1314) configured to come into contact with a terminal of a secondary battery (112, 312, 512, 712, 912, 1012), and an insulating member (130, 230, 430, 630, 830, 930, 1030, 1130, 1230, 1316) configured to cover at least a part of the head (122, 222, 422, 1100, 1314).