Battery Confluence Component With Recessed Vibration-Absorbing Body
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Solution Overview
Problem
Confluence components in batteries are prone to fatigue fracture due to stress concentration and repeated stress from relative vibrations between battery cells, leading to high voltage connection failures and reduced reliability.
Innovation Solution
A confluence component with a recessed main body part that is deformable under stress, made of a low hardness material, to absorb vibrations and prevent fatigue fracture, while the connection parts are reinforced with multi-layer materials and plating layers for enhanced strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the confluence component is made with a simple structure connecting battery cells, then the manufacturing process is simple, but the component is prone to fatigue fracture due to stress concentration from vibrations
Solution Approach 1:
The confluence component features a recessed portion with reduced thickness creating a localized stress relief zone. This recessed structure concentrates the vibration absorption function in a specific area, allowing the rest of the component to maintain simple geometry for easy manufacturing. The recessed portion acts as a dedicated vibration absorption zone that prevents stress concentration in critical connection areas.
Solution Approach 2:
The recessed portion is designed in advance to absorb vibrations before they can cause fatigue fracture in the connection regions. By providing this cushioning structure beforehand, the component can withstand repeated vibrations without compromising the reliability of the battery cell connections, preventing failure before it occurs.
2Strength
If the confluence component is made rigid to maintain structural stability, then the connection strength is high, but the component cannot absorb vibrations and is prone to fatigue fracture
Solution Approach 1:
The confluence component employs different structural properties in different regions: the connection portions maintain high strength and rigidity for stable electrical connections, while the recessed portion has reduced thickness and increased flexibility to absorb vibrations. This local differentiation allows the component to simultaneously achieve both structural strength and vibration resistance.
Solution Approach 2:
The confluence component is segmented into functionally distinct regions: rigid connection portions for structural integrity and a flexible recessed portion for vibration absorption. This segmentation allows each region to be optimized for its specific function, with the connection parts maintaining high strength while the recessed part provides vibration cushioning.
3Ease of manufacture
If the confluence component has uniform thickness for simplicity, then the manufacturing process is easy, but the component cannot effectively absorb vibrations in the thickness direction
Solution Approach 1:
Instead of uniform thickness, the confluence component features a locally modified recessed portion with reduced thickness specifically positioned to absorb vibrations in the thickness direction. This localized thickness variation maintains relative manufacturing simplicity while effectively addressing the vibration harm by creating a compliant zone that can deform to absorb vibrational energy.
4Ease of manufacture
If the confluence component uses a single material for simplicity, then the manufacturing process is simple, but the component cannot simultaneously achieve connection strength and vibration absorption
Solution Approach 1:
The confluence component uses a single material throughout for manufacturing simplicity, but achieves functional versatility through geometric variation. The recessed portion's reduced thickness creates localized compliance that enables vibration absorption, while the thicker connection portions maintain structural strength. This approach achieves multi-functionality through form rather than material composition.
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 solution effectively absorbs vibrations, preventing fatigue fractures and improving the reliability of the confluence component and overall battery connection, ensuring stable electrical connections even in harsh environments with frequent vibrations.
Implementation Method 1
the main body part is at least partially recessed and is deformable under a preset stress to absorb vibrations in the thickness direction
Data Source
AI summary
A confluence component includes a main body part and two connection parts connected to two sides, respectively, of the main body part in a length direction of the confluence component. Each of the connection parts includes a connection region electrically connected to a battery cell. In a thickness direction of the confluence component, the main body part is at least partially recessed and is deformable under a preset stress to absorb vibrations in the thickness direction.