Battery Interconnect Member With Vibration Damping Portion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ultrasonic welding of interconnect members to battery terminals can cause vibrations that degrade prior weld joints, leading to reduced reliability and performance in battery modules.
Innovation Solution
The use of interconnect members with vibration dampening portions, constructed from multiple plate portions of varying thicknesses, which are coupled to attenuate vibrations and reduce the transmission of stress to other regions, thereby minimizing the degradation of weld joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to couple interconnect members to battery terminals, then electrical connection is achieved, but vibrations are transmitted through the interconnect member which degrade prior weld joints
Solution Approach 1:
The interconnect member is divided into multiple plate portions (first plate portion, second plate portion, third plate portion) with different thicknesses. The thinner plate portions (first and second) are used at weld locations to minimize vibration generation, while the thicker plate portion (third) is positioned between weld locations to dampen vibrations and protect prior weld joints from degradation.
Solution Approach 2:
Different regions of the interconnect member are assigned different thicknesses based on their functional requirements. The plate portions at weld locations have a first thickness optimized for welding, while the intermediate plate portion has a second thickness greater than the first thickness to provide vibration damping. This local variation in geometry allows each region to perform its specific function optimally.
2Reliability
If interconnect member thickness is increased to dampen vibrations, then weld joint degradation is reduced, but device complexity increases
Solution Approach 1:
Rather than uniformly increasing the thickness of the entire interconnect member, the structure is segmented into multiple plate portions with different thicknesses. This allows vibration damping to be achieved locally at critical regions (intermediate plate portions) without unnecessarily increasing the thickness elsewhere, thereby maintaining structural simplicity where possible.
Solution Approach 2:
The interconnect member features localized thickness variations rather than a uniform thick design. The plate portions at weld locations maintain a thinner first thickness for welding compatibility, while only the intermediate portions between welds have increased thickness for vibration damping. This localized approach reduces overall device complexity compared to a uniformly thick design.
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 implementation of vibration dampening portions in interconnect members effectively reduces the degradation of weld joints during ultrasonic welding, enhancing the reliability and longevity of battery module connections.
Implementation Method 1
a first vibration dampening portion coupled to the first and second plate portions. The first vibration dampening portion has a third thickness greater than the first thickness, such that vibrations induced on the first plate portion are attenuated when a portion of the vibrations pass through the first vibration dampening portion to the second plate portion
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Battery modules having interconnect members are provided. An interconnect member includes a first plate portion having a first thickness. The interconnect member further includes a second plate portion having a second thickness equal to the first thickness. The second plate portion extends generally parallel to the first plate portion. The interconnect member further includes a first vibration dampening portion coupled to the first and second plate portions. The first vibration dampening portion has a third thickness greater than the first thickness, such that vibrations induced on the first plate portion are attenuated when a portion of the vibrations pass through the first vibration dampening portion to the second plate portion.