Wire Helix Threaded Formation for Battery Electrodes
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Solution Overview
Problem
Existing thread formation technologies for wire helices face challenges in minimizing material penetration during overmoulding, particularly with plastic, and require complex assembly processes, which increase production costs and complexity.
Innovation Solution
A wire helix design featuring an engagement recess on one side and a projection on the opposite side, allowing for a form-fitting connection without the need for clamping, along with a thread contour on additional sides for enhanced adhesion and conductivity, using materials like metallic alloys for efficient thread formation in battery applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If wire helix windings are formed convex/concave to achieve regular strip with minimal material penetration, then material penetration is reduced, but production complexity increases
Solution Approach 1:
The wire cross-section is segmented into distinct functional zones: engagement recesses on opposite sides for lateral joining, thread contours on two sides for thread formation, and a fourth side for adhesion. This segmentation allows each zone to perform its specific function independently, reducing material penetration while maintaining production simplicity.
Solution Approach 2:
The engagement recesses and projections are pre-formed on the wire before coiling into a helix. This preliminary preparation enables automatic form-fitting connection during assembly without requiring complex clamping operations, thereby reducing both material penetration and production complexity.
2Strength
If wire sections are joined by pressing together with clamping effect, then connection strength is improved, but assembly complexity increases
Solution Approach 1:
The wire sections are designed with engagement recesses and projections that automatically engage with each other when the wire is laterally displaced during coiling. This self-service mechanism creates a form-fitting connection without requiring external clamping devices or complex assembly operations, maintaining connection strength while simplifying assembly.
3Reliability
If thread contour is formed on wire for battery connector application, then electrical conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
The wire cross-section is designed to serve multiple functions simultaneously: engagement recesses for joining, thread contours for thread formation, and a fourth side for adhesion. This multi-functional design allows a single wire structure to perform all necessary functions, improving electrical conductivity for battery connectors while maintaining manufacturing simplicity through a unified production process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces material penetration during casting, simplifies assembly, and enables cost-effective production of battery connectors with improved electrical conductivity and adhesion, while allowing for the use of harder, more conductive metals for thread formation.
Implementation Method 1
An elastic deformability of the wire material can be used for such a locking connection
Implementation Method 2
this results in a large area in which adhesion to the encapsulated metal is provided
Implementation Method 3
a material with good electrical conductivity, for example also a metallic alloy
Data Source
AI summary
The invention relates to a threaded formation (1) made of a wire (2), which runs in the form of a wire coil having a direction of extension corresponding to a central axis (M) and which forms a nut or a screw, optionally in the form of a threaded opening in or of a threaded pin on a component. In order to achieve maximum stability in the direction of extension of the wire coil, the wire (2) holds itself in position in form-locked manner in the direction of extension of the central axis (M) of the wire coil. The invention further relates to a battery electrode or battery pole (13) made of an electrode metal such as lead, zinc, copper or an alloy of nickel and cadmium. In order to design the electrically conductive connection of the battery electrode or of the battery pole as efficiently as possible, the battery electrode or the battery pole (13) are formed by casting with an electrode metal that has a threaded formation (1) made of a wire (2) which runs in the form of a wire coil having a direction of extension, preferably a central axis (M), and which corresponds to a nut or a screw, optionally in the form of a threaded opening in or a threaded pin on the battery electrode or the battery pole (13).