Non-Circular Conductive Member Head Prevents Rotation During Swaging
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Solution Overview
Problem
In energy storage devices, such as batteries and capacitors, the conductive member can rotate during swaging, leading to displacement from its desired position and potential electrical issues.
Innovation Solution
A conductive member with a main body part having a central axis and a non-circular head is used, where the head is supported during swaging to prevent rotation, and an insulating member is employed to secure the conductive member in place, ensuring electrical coupling and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductive member is swaged to integrate it with the case, then the electrical connection is secured, but the conductive member may rotate around the rotation axis causing displacement from desired position
Solution Approach 1:
The head of the conductive member is designed with an asymmetric non-circular cross-section that fits into a corresponding asymmetric recess in the case. This asymmetric geometry prevents rotation of the conductive member around its longitudinal axis during swaging, ensuring the conductive member remains in its desired position while still allowing the swaging force to integrate the electrical connection.
2Reliability
If the conductive member is swaged to integrate it with the case, then the electrical connection is secured, but the coupling conductor may be displaced from desired position
Solution Approach 1:
The asymmetric non-circular head design directly prevents rotation of the conductive member, which in turn prevents displacement of the coupling conductor. By eliminating the rotation degree of freedom through asymmetric geometry, both the conductive member and coupling conductor maintain their desired positions during the swaging process.
3Ease of manufacture
If a circular head is used on the conductive member, then the manufacturing is simpler, but the conductive member can rotate during swaging
Solution Approach 1:
The head is designed with a non-circular asymmetric cross-section that is still manufacturable using standard forging or forming processes. The asymmetric shape can be created in a single forming operation, maintaining ease of manufacture while adding the critical anti-rotation function that circular geometry cannot provide.
Data Source
AI summary
A energy storage device includes: an electrode assembly that includes a positive electrode plate and a negative electrode plate, the positive electrode plate and the negative electrode plate being mutually insulated; a case that houses the electrode assembly; and a conductive member electrically coupled to the electrode assembly in the case. The conductive member includes a main body part that has a central axis in a direction passing through a wall surface of the case, and a conductive connection part that protrudes from the main body part in a direction intersecting with the central axis. The main body part includes a swage portion disposed at one end portion of the main body part and inserted into the wall surface of case, and a non-circular head disposed at another end portion of the main body part.