Battery Module Sampling Connection for Vibration-Resistant Welding
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Solution Overview
Problem
The reliability of secondary battery voltage collection in battery modules is compromised due to the potential breaking of connection sheets at welded positions, caused by expansion or vibration of secondary batteries, which can lead to failure in voltage collection.
Innovation Solution
A connection structure is introduced where the sampling leg and busbar are connected via a connector located closer to the sampling circuit board, decomposing tensile forces and reducing stress on the welded zone, thereby preventing tearing or breaking of the sampling leg.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sampling leg is rigidly welded to the busbar, then the electrical connection is reliable, but the welded zone is susceptible to breaking when the secondary battery expands or vibrates
Solution Approach 1:
The connection between the sampling leg and busbar is divided into two separate connection structures: a welded zone for electrical connection and a connector (such as a riveting member or buckle) for mechanical support. This segmentation allows each connection structure to perform its specific function independently, preventing the welded zone from bearing excessive tensile forces during battery expansion or vibration.
Solution Approach 2:
A connector (intermediary component) is introduced between the sampling leg and busbar to act as a mediator that absorbs and decomposes tensile forces. The connector, positioned closer to the sampling circuit board, serves as a buffer that protects the welded zone from direct mechanical stress while maintaining both electrical and mechanical connections.
2Area of stationary object
If the connector is positioned far from the sampling circuit board, then the welding area is larger, but the tensile force on the welded zone increases when the sampling leg moves
Solution Approach 1:
The connector is pre-positioned closer to the sampling circuit board before the battery undergoes expansion or vibration. This preliminary positioning ensures that when tensile forces occur, the connector is already in place to decompose and absorb these forces, protecting the welded zone from excessive stress while maintaining an adequate welding area.
3Force
If the sampling leg is allowed to move relative to the busbar, then the connection structure can decompose tensile force, but the electrical connection stability may be compromised
Solution Approach 1:
The solution merges two distinct connection structures (welded zone for electrical connection and connector for mechanical support) into a unified connection system. This combined structure allows the sampling leg to have controlled movement capability through the connector while maintaining stable electrical connection through the separate welded zone, achieving both tensile force decomposition and electrical connection stability simultaneously.
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
This solution effectively reduces the likelihood of connection failure and enhances the safety and reliability of battery modules by distributing tensile forces through the connection structure, rather than the welded zone, thus maintaining stable voltage collection.
Implementation Method 1
The sampling leg and the busbar are welded together to form a welded zone
Implementation Method 2
The connection structure can decompose a tensile force, which is beneficial to reduce the tensile force borne by the welded zone
Data Source
AI summary
The application relates to a battery module, a battery pack and a vehicle. The battery module includes: secondary batteries, in which two or more secondary batteries are arranged side by side in an arrangement direction; a busbar arranged on a top of the secondary batteries and electrically connected to at least two of the secondary batteries; a sampling assembly including a sampling circuit board arranged on the top of the secondary batteries and a sampling leg extending from the sampling circuit board toward the busbar, the sampling leg and the busbar being welded to form a welded zone; a connector, the sampling leg and the busbar being connected by the connector, the connector being located at a side of the welded zone close to the sampling circuit board.