Single-Ended Cylindrical Cell Connector to Prevent Electrical Shorts
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Solution Overview
Problem
Existing cylindrical battery cell connectors for tall cells with smaller base diameters than heights face issues of increased material cost, restricted insertion angles, and a higher risk of electrical shorts due to running conductors along the cell's height.
Innovation Solution
A single-ended cylindrical battery cell connector with a nonconductive outer shell, a cylindrical inner cavity, and terminals positioned to prevent simultaneous contact of anode and cathode, featuring a positive terminal near the base and a negative terminal on the inner wall, reducing the likelihood of electrical shorts and minimizing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrical conductor is run for the height of the cell cylinder, then electrical connection is achieved, but material cost increases and the likelihood of electrical short increases
Solution Approach 1:
The patent transitions from a vertical conductor arrangement (running along the height of the cell) to a radial/dimensional arrangement where conductors extend from the base outward. This dimensional change allows electrical connection while reducing conductor length and eliminating the need for tall insulating structures.
Solution Approach 2:
The patent extracts the conductor from the vertical path along the cell height and repositions it to extend from the base outward. This separation removes the harmful interaction between the conductor and the tall cell structure, eliminating the risk of electrical short while maintaining electrical connection functionality.
2Reliability
If an electrical conductor is run for the height of the cell cylinder, then electrical connection is achieved, but material cost increases
Solution Approach 1:
The patent transitions from a vertical conductor arrangement (running along the height of the cell) to a radial/dimensional arrangement where conductors extend from the base outward. This dimensional change allows electrical connection while reducing conductor length and eliminating the need for tall insulating structures.
Solution Approach 2:
The patent extracts the conductor from the vertical path along the cell height and repositions it to extend from the base outward. This separation removes the harmful interaction between the conductor and the tall cell structure, eliminating the risk of electrical short while maintaining electrical connection functionality.
3Adaptability or versatility
If a connector accommodates tall cylindrical battery cells, then cell insertion is enabled, but the angle of insertion and removal is restricted
Solution Approach 1:
The patent changes the insertion geometry from a vertical orientation (requiring precise angular alignment) to a horizontal orientation where the cell base inserts into the connector. This dimensional change provides greater operational flexibility and eliminates angular insertion restrictions.
Solution Approach 2:
Instead of having the cell insert vertically into a tall connector structure, the patent inverts the arrangement so the cell base inserts horizontally into a shallow connector. This inversion of the insertion geometry fundamentally improves ease of operation while maintaining adaptability to tall cylindrical cells.
Data Source
AI summary
The present disclosure describes a battery connector for cylindrical battery cells having a positively charged anode contiguous with the circular, or oval, first end, a negatively charged cathode contiguous with the circular, or oval, second end, and straight parallel sides electrically connected with said cathode. The battery connector has an electrically nonconductive outer shell, open-ended on one side, with a cylindrical inner cavity into which one end of the battery cell is inserted. In the preferred embodiment, the nonconductive outer shell is comprised of plastic. In another embodiment, the nonconductive outer shell may be comprised of a Silicon-based material, but other embodiments are also possible. In the preferred embodiment, the nonconductive outer shell is sufficiently tall, and the cylindrical cavity's diameter is sufficiently narrow, to substantially prevent either the anode or the cathode of the battery cell from contacting both battery terminals simultaneously.