3D Battery Cell Connector Geometry for Support and Vibration Damping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Battery cell connections in vehicles lack mechanical support and vibration damping, leading to potential mechanical and electrical failures due to shape tolerances and vibrations.
Innovation Solution
The development of battery cell connectors made from sheet metal with bends and turns that provide mechanical rigidity and vibration damping, forming a three-dimensional structure to support battery cell terminals and absorb vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are connected using traditional cables, then electrical connection is achieved, but mechanical support and vibration damping are insufficient
Solution Approach 1:
The patent combines electrical connection and mechanical support functions into a single integrated connector structure. The connector includes rigid support elements and flexible damping elements that work together to provide both electrical conductivity and mechanical stability, eliminating the need for separate cable and support components.
Solution Approach 2:
The connector utilizes composite construction with rigid portions (providing structural support) and flexible portions (providing vibration damping). This composite approach allows the single component to deliver both mechanical strength and shock absorption capabilities simultaneously.
2Strength
If rigid connectors are used to provide mechanical support, then structural stability improves, but vibration damping capability deteriorates
Solution Approach 1:
The connector features localized rigid portions at connection points for structural support, while incorporating flexible damping portions in intermediate sections to absorb vibrations. This spatial differentiation of mechanical properties allows simultaneous achievement of rigidity where needed and vibration isolation where beneficial.
Solution Approach 2:
The flexible portions of the connector incorporate curved or bent geometries that enable elastic deformation to absorb vibrational energy, while the rigid portions maintain straight or angular configurations for structural support. The curved sections act as mechanical springs to dampen shocks.
3Object-affected harmful factors
If flexible connectors are used to dampen vibrations, then vibration damping improves, but mechanical rigidity and load-bearing capacity deteriorate
Solution Approach 1:
The connector is divided into distinct rigid segments and flexible segments along its length. The rigid segments carry primary mechanical loads and provide structural support, while the flexible segments are positioned to absorb vibrations and shocks, creating a segmented structure that optimizes both load-bearing and damping functions.
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
The connectors offer enhanced mechanical support and vibration damping, reducing the risk of mechanical and electrical failures in battery systems by efficiently carrying bending and shear loads and damping vibrations.
Implementation Method 1
The battery cell connector includes a plurality of bends coupling the plurality of segments together into a three-dimensional (3-D) object... the bends coupling segments act a stiff springs that provide vibration damping along one or more rotational axes
Implementation Method 2
the bends coupling segments act a stiff springs that provide vibration damping
Implementation Method 3
disclosed arc battery module connectors that provide mechanical support and/or vibration damping... segments of substantially flat sheets of metal that efficiently carry bending and shear loads along a longitudinal direction of each segment
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery cell connector includes a plurality of segments. Each segment defines a respective plane and has a respective longitudinal axis. The battery cell connector further includes a plurality of bends coupling the plurality of segments together into a 3-D object, each bend located between a unique pair of adjacent segments of the plurality of segments, where the unique pair of adjacent segments define two distinct respective planes. A first segment of the plurality of segments includes one or more first connecting elements for a battery pole of a first battery cell and a second segment of the plurality of segments includes one or more second connecting elements for a battery pole of a second battery cell. The one or more first connecting elements are electrically coupled with the one or more second connecting elements.