Rounded Battery Tab Connection to Cut Pin Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Battery pins in existing 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 cross-sectional circumference L1 and a main body portion thickness L2, where L1=aL2 and π ≤ a < 10, forming a double-layer structure with symmetric connecting sheets to reduce 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 assembly process is simplified, 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 cross-section where the outer circumference L1=aL2, a is a first coefficient, and π≤a. This curved geometry eliminates sharp angles that would extend the current flow path, allowing the pin to bend while maintaining a short electrical path and low resistance, thus resolving the contradiction between ease of assembly and electrical performance
2Reliability
If the battery pin uses a rounded bent portion with specific geometry, then resistance is reduced and current flow capability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent defines specific parameter ranges for the bent portion geometry, including the outer circumference L1=aL2 where a is a first coefficient and π≤a, and the thickness ratio bL1≤L3<L2 where b is a second coefficient and 0<b<1. These parameter specifications provide clear manufacturing targets while allowing flexibility within defined ranges, balancing precision requirements with manufacturability
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present application provides an electrode tab connecting structure, a battery, and a welding detection system. 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 (103) is L2, L1=aL2, a is a first coefficient, and π ≤ a < 10.