Vehicle Battery PCB Tabs for Vibration-Resistant Cell Contacts
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Solution Overview
Problem
Existing electric battery interconnection methods, such as welding and elastically deformable contact elements, are not satisfactory due to complexity, cost, and inability to withstand vibrations and impacts, making assembly and refurbishment difficult.
Innovation Solution
A battery design featuring printed circuit boards with elastically deformable tabs formed by slots, allowing contact elements to maintain connection with cell terminals without specialized resistance to vibrations, using standard and simple components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to interconnect cells with connecting tapes, then reliable electrical connection is achieved, but the battery cannot be dismantled for servicing or reconditioning
Solution Approach 1:
The connecting tape is segmented into modular sections that can be independently removed from each cell terminal, allowing the battery to be dismantled cell-by-cell for servicing while maintaining reliable connection during operation
Solution Approach 2:
The connecting tape is pre-designed with removable connection features that enable easy disassembly for maintenance while ensuring secure electrical connection during normal operation
2Reliability
If elastically deformable contact elements are used to resist vibrations, then contact reliability under vibration is improved, but the electronic card becomes complex to manufacture and contact elements must be specifically designed
Solution Approach 1:
The contact elements use standard rigid components rather than specially designed elastic ones, and achieve vibration resistance by changing the mechanical parameters of the overall assembly structure rather than the contact elements themselves
Solution Approach 2:
Standard rigid contact elements serve multiple functions: providing electrical connection and accommodating vibration through the overall assembly design, eliminating the need for specialized elastic contact elements
3Device complexity
If standard contact elements are used without specialized vibration resistance, then manufacturing complexity and cost are reduced, but contact reliability under vibration and impact deteriorates
Solution Approach 1:
The connecting tape structure acts as an intermediary that absorbs and isolates vibration and impact forces from the standard rigid contact elements, protecting them while maintaining simple 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 design ensures reliable contact between cells and circuit boards under vibration, simplifies assembly, reduces costs, and allows easy cell replacement.
Implementation Method 1
each slot defining a tab that is elastically deformable with respect to the main portion
Data Source
AI summary
The invention relates to an electric battery (1) comprising: a plurality of electric charge cells (2), each cell having end faces (21, 22) that are located on opposite sides of the cell, each end face being provided with a contact terminal (23); at least one first printed circuit board (41) arranged in line with the end faces that are located at one of the sides of the cells, the printed circuit board being provided with a plurality of first electrical connection elements (43), each of the first electrical connection elements being located facing one of the contact terminals of the cells; characterized in that the first printed circuit board comprises a main portion (44) in which a plurality of slots (45) are formed, each slot defining a tab (46) that is elastically deformable with respect to the main portion, each first electrical connection element being arranged on one of the tabs of the first printed circuit board.