3D Battery Cell Connector Structure for 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
Battery cell connectors are designed with segmented metal sheets that provide mechanical rigidity and vibration damping through bends and turns, forming a three-dimensional structure that efficiently carries bending and shear loads, and acts as stiff springs to dampen 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 connector is divided into multiple segments including a first segment for the first battery cell, a second segment for the second battery cell, and an intermediate segment connecting them. This segmentation allows each segment to be optimized for its specific function while working together to provide both electrical connection and mechanical support.
Solution Approach 2:
The connector transitions from a two-dimensional cable to a three-dimensional structure with bends and turns. The intermediate segment includes bends that extend in directions perpendicular to the longitudinal axes of the terminal segments, creating a rigid spatial framework that provides mechanical support in multiple directions.
2Strength
If a rigid connector structure is used to provide mechanical support, then vibration damping may be reduced, but mechanical strength is improved
Solution Approach 1:
The intermediate segment is designed with bends that can deform elastically under vibration loads. While the overall connector maintains rigidity for mechanical support, the intermediate segment can dynamically absorb vibration energy through controlled deformation, preventing vibration transmission between battery cells.
Solution Approach 2:
The intermediate segment with its bend configuration acts as a pre-designed vibration isolation element. The bends are positioned and configured to provide cushioning against expected vibration forces before they can cause damage to the battery cell connections.
3Adaptability or versatility
If the connector accommodates shape tolerances between battery cells, then adaptability is improved, but precision of alignment may be compromised
Solution Approach 1:
The connector design allows for parameter variations in the positions and orientations of the terminal segments while maintaining functional integrity. The intermediate segment's bend configuration can accommodate variations in battery cell dimensions and positions within tolerance ranges, providing adaptability without requiring high-precision manufacturing.
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 securely connecting battery cells while accommodating existing geometries and absorbing vibrations.
Implementation Method 1
The segments are coupled by bends and/or turns... that efficiently carry bending and shear loads... and acts as stiff springs to dampen vibrations
Implementation Method 2
The segments are coupled by bends and/or turns... that efficiently carry bending and shear loads
Implementation Method 3
The segments are coupled by bends and/or turns... that efficiently carry bending and shear loads
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.