Battery Connection Flexure for Vibration Resistance
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Solution Overview
Problem
Existing energy-storage devices, such as battery packs, face disconnection issues due to vibrations and shocks, which can lead to electrical interface failures between cell terminals and weld straps, causing potential damage and safety hazards.
Innovation Solution
The implementation of a conductive sheet with flexures and curved edges that allow relative motion between cells, reducing the likelihood of disconnection by accommodating mechanical stress and absorbing forces, thereby maintaining a stable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid connections are used between battery cells and weld straps, then electrical connection stability is improved, but susceptibility to vibration-induced disconnection increases
Solution Approach 1:
The weld strap is designed with a flexure portion that allows dynamic movement and flexibility. This enables the rigid electrical connection to adapt to vibrations and shocks by allowing controlled movement in the flexure region, preventing disconnection while maintaining electrical stability.
Solution Approach 2:
The weld strap incorporates a flexure portion with curved edges that acts as a flexible element. This flexible portion absorbs mechanical stress from vibrations and shocks, protecting the electrical connection between battery cells and weld straps from failure.
2Object-affected harmful factors
If flexible connections are used between battery cells and weld straps, then resistance to vibration-induced disconnection is improved, but electrical connection stability deteriorates
Solution Approach 1:
The flexure portion is designed with specific curvature and structural characteristics that allow it to be flexible enough to absorb vibrations while maintaining sufficient rigidity to ensure stable electrical connection. The dynamic properties are optimized to balance flexibility and connection stability.
Solution Approach 2:
Different portions of the weld strap have different mechanical properties. The flexure portion has higher flexibility to resist vibrations, while the contact portions with battery cells maintain sufficient rigidity for stable electrical connection. This local differentiation of mechanical properties resolves the contradiction.
3Object-affected harmful factors
If curved edges with high curvature are used in the flexure, then flexibility and vibration absorption are improved, but structural strength deteriorates
Solution Approach 1:
The curvature parameter of the flexure edges is optimized to achieve the right balance. The curved edges have sufficient curvature to provide flexibility and vibration absorption, but the curvature is controlled within limits to maintain adequate structural strength for the application.
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 enhances the operational safety and reliability of energy-storage devices by reducing the risk of electrical interface failures and maintaining power output under varying mechanical conditions.
Implementation Method 1
A curvature of the curved edge flexibly changes in response to a motion of the first contact relative to a second contact
Data Source
AI summary
Example energy-storage implementations are provided. One example implementation involves a device that has a gap extending between a first side of the device and a second side opposite to the first side. The first side is to overlap a first cell and a second cell. The device includes a first contact to couple with the first cell and a second contact to couple with the second cell. The device also includes a flexure having a curved edge adjacent to the gap. The curved edge extends from a first end positioned to overlap with the first cell to a second end positioned to overlap with the second cell. A curvature of the curved edge flexibly changes in response to a motion of the first contact.