Key Points Of Battery Connector Design
Jul 09, 2025
- Reasonable design by design engineers can save 20% of material costs before the stamping process of battery connectors. The outer edge of the battery connector should be designed with rounded corners as much as possible.
- The distance between the card and the edge line should be at least 0.2mm, and the width of the product material only needs to be 32mm. Therefore, when designing the mold, the shared edge line must be pre cut out first, otherwise the continuous mold will rub and deform the already punched card when punching the edge line.
- At the same time, it is advisable not to design battery connectors with solder pins, as designing solder pins solely to secure the battery cells may double the material cost of the battery spring. If you are concerned about the stability of battery cells after installation, you can focus on the design of battery spring clips.
- Avoid design redundancy: During the design process, redundant parts should be avoided as much as possible to improve the practicality and economy of battery connectors. For example, avoid designing unnecessary soldering pins, reduce material costs, and streamline production processes.
- Reasonable specifications and dimensions: Determine the specifications and dimensions of the first effective area based on the welding area between the connecting piece and the pole ear. The center to center distance between adjacent positioning holes is 20-25mm, and the diameter of the positioning holes is 3-5mm. These reasonable specifications and dimensions help improve the performance and stability of battery connectors.
- Enhance overcurrent capability: Setting up reinforced structures and slots can enhance overcurrent capability. By setting up a reinforcement structure and a slot on one side of the connecting piece body, the structural strength of the connecting piece body can be increased through the setting of the reinforcement structure, and the setting of the slot can facilitate the infiltration and circulation of electrolyte. By setting a flange on the outer edge of the connecting piece body, the welding area between the connecting piece and the shell can be increased, enhancing the overcurrent capacity and achieving high rate charging and discharging of the battery cell.
