Flexible Battery Module Connector for Vibration-Stable Bus Bar Links

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Solution Overview

Problem

Existing battery packs face challenges in maintaining stable electrical connections between modules due to vibrations, which can lead to separation and reduced performance, especially in applications like electric vehicles where impact and displacement are common.

Innovation Solution

A battery pack design featuring a conductive connector with a flexible structure, including a thin metal plate with concave and convex portions capable of XYZ axis displacement, connected to bus bars through conductive dampers, to absorb vibrations and maintain electrical connectivity between battery modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid connector is used to connect battery modules, then electrical connection is established, but the connection becomes unstable under vibration and displacement conditions

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidvibration impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The connector is designed with a displacement portion that can dynamically move in XYZ directions to adapt to battery module displacement caused by vibrations. This dynamic capability allows the rigid connector to maintain stable electrical connection despite external vibrations and module movements.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connector's displacement portion is designed to change its positional parameters (X, Y, Z coordinates) in response to vibration and displacement conditions. By allowing parameter changes rather than maintaining fixed parameters, the connector maintains reliable electrical connection under varying conditions.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a flexible structure is introduced to absorb vibration, then connection stability improves, but device complexity increases

Engineering Contradiction:

Improveconnection stability under vibrationVSAvoidconnector structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connector is segmented into three functional portions: a first connection portion, a displacement portion, and a second connection portion. This segmentation allows the displacement portion to specifically handle vibration absorption while the connection portions maintain electrical connectivity, resolving the contradiction between flexibility and complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The displacement portion is designed as a thin-walled structure that can flex and deform to absorb vibrations. This thin-film approach provides the necessary flexibility for vibration damping while maintaining a relatively simple overall structure compared to more complex flexible mechanisms.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If the connector is designed to accommodate XYZ axis displacement, then adaptability to module movement improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvedisplacement accommodation capabilityVSAvoidconnector fabrication tolerance

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The displacement portion is designed with dynamic freedom to move in XYZ directions, which inherently accommodates manufacturing tolerances. Rather than requiring extremely precise manufacturing to achieve displacement accommodation, the design allows the structure to naturally adapt through its dynamic displacement capability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The thin-walled displacement portion can deform and flex to accommodate XYZ axis displacements, which reduces the need for high manufacturing precision. The flexible thin-film structure naturally absorbs dimensional variations through its deformability, lowering fabrication tolerance requirements.

Inventive Principle:

Principle #30Flexible shells and thin films

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 flexible conductive connector effectively absorbs vibrations and maintains electrical connections between battery modules, ensuring stable performance and preventing damage from displacement, thus providing reliable power to devices like electric vehicles.

Implementation Method 1

Methodology Applied

Scientific EffectVibration absorption: Damping

Implementation Method 2

The displacement portion may be configured as a flexible structure including a concave portion and a convex portion that are alternately positioned.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20250007102A1Battery pack

Publication Date: 2025.01.02 SAMSUNG SDI CO LTD

AI summary

A battery pack includes a first battery module including first battery cells and a first bus bar electrically connected to the first battery cells, a second battery module including second battery cells and a second bus bar electrically connected to the second battery cells, and a conductive connector connected to the first bus bar and the second bus bar, the conductive connector having a first connection portion connected to the first bus bar, a second connection portion connected to the second bus bar, and a displacement portion between the first connection portion and the second connection portion, the displacement portion being moveable in each of X-axis, Y-axis, and Z-axis directions.