Battery Module Clamping-Sampling Member for Vibration-Resistant Wire Harness
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Solution Overview
Problem
Current methods for fixing wire harnesses in battery modules, such as ultrasonic welding and aluminum wire bonding, result in low strength connections that can fail under vibration impacts, and laser welding requires high flatness, leading to low peel strength and reliability issues.
Innovation Solution
A battery module design featuring a clamping-sampling member with a wire connection portion and a clamping portion that securely attaches the wire harness to a connecting member, enhancing the connection strength by clamping rather than welding, and incorporating a U-shaped wire connection portion and protrusions for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic welding or aluminum wire bonding welding is used to fix the wire harness to the connecting member, then the wire harness can be fixed, but the connection strength is relatively low and the wire harness may easily break under vibration impacts
Solution Approach 1:
The patent replaces welding-based mechanical connections (ultrasonic welding, aluminum wire bonding) with a clamping mechanism that uses elastic deformation and friction force. The clamping member applies continuous pressure to the wire harness through elastic deformation, creating a friction-based connection that is more reliable under vibration than welding joints.
Solution Approach 2:
The patent changes the connection mechanism from permanent welding to adjustable clamping force. The clamping member can be designed with specific elastic modulus and cross-sectional area to achieve optimal clamping force, allowing parameter optimization for different wire harness types and vibration conditions.
2Ease of manufacture
If laser welding is used to fix the wire harness to the connecting member, then welding can be achieved, but high flatness is required for the connecting member resulting in low peel strength
Solution Approach 1:
The patent replaces laser welding with a mechanical clamping system that does not require high flatness of the connecting member. The clamping member can accommodate surface irregularities through its elastic deformation capability, eliminating the need for precise surface preparation and achieving higher peel strength.
3Ease of manufacture
If welding methods are used to fix the wire harness, then the wire harness can be connected, but the connection may fail easily under long-term cycle use of the battery
Solution Approach 1:
The patent introduces dynamic characteristics to the connection system through the elastic clamping member. The clamping member can dynamically adjust to thermal expansion, vibration, and other environmental factors during battery cycling, maintaining connection reliability over long-term use unlike rigid welding joints.
Data Source
AI summary
The present disclosure relates to a battery module, including two or more battery cells, each including an electrode terminal; a connecting member, wherein the electrode terminals of adjacent battery cells are connected by the connecting member; and a clamping-sampling member, including a wire connection portion for fixing a wire harness and a clamping portion, wherein one end of the clamping portion is connected with the wire connection portion and the other end of the clamping portion clamps the connecting member.