Rounded Battery Pin Tab Structure for Lower Welding Resistance
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Solution Overview
Problem
Battery pins in related technologies have an extended current flow path and increased resistance due to vertically bent sections during the welding and bending process.
Innovation Solution
The electrode tab connecting structure features a rounded bent portion with a specific coefficient relationship (π≤a<10) and a double-layer structure, reducing the outer perimeter of the bent portion to minimize resistance and enhance current flow capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the battery pin is bent vertically during the welding and bending process, then the battery pin can be connected to the electrode tab, but the current flow path is extended and resistance increases
Solution Approach 1:
The bent portion of the battery pin is designed with a rounded outer side face instead of a sharp vertical bend. The curvature radius is specifically controlled to be between 0.5-2mm, which reduces the path length of current flow through the bent portion while maintaining the necessary mechanical flexibility for connection.
Solution Approach 2:
The patent optimizes the geometric parameters of the bent portion, specifically the curvature radius and the angle of bending. By changing these parameters, the current flow path is minimized while still achieving the required mechanical connection between the battery pin and electrode tab.
2Ease of manufacture
If the battery pin structure is simplified, then manufacturing is easier, but the structural strength may be compromised
Solution Approach 1:
The battery pin is divided into distinct functional portions: a welding portion for joining to the electrode tab, a bent portion for forming the connection angle, and a terminal portion for electrical connection. This segmentation allows each portion to be optimized independently for its specific function while maintaining overall structural integrity.
Solution Approach 2:
The battery pin utilizes material composition and structural composite design where the bent portion has specific dimensional relationships (curvature radius to thickness ratio) that provide both mechanical strength and electrical conductivity. The structured design creates a composite effect that maintains strength while enabling simplified manufacturing.
Data Source
AI summary
An electrode tab connecting structure, a battery, and a welding detection system are provided in the present application. The electrode tab connecting structure includes a battery pin, and the battery pin includes an electrode terminal connecting portion and an electrode tab connecting portion. The electrode tab connecting portion includes a bent portion, a main body portion, and a connecting sub-portion. An outer side face, facing away from the main body portion and the connecting sub-portion, of the bent portion is arranged to be rounded. An outer circumference of a cross section of the bent portion is L1, a thickness of the main body portion is L2, L1=aL2, a is a first coefficient, and π≤a<10.