Multi-directional Bent Connection Member for Battery Vibration Absorption
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Solution Overview
Problem
Existing power storage devices face challenges in securely connecting bus bars to cylindrical batteries due to assembly tolerance and vibration-induced displacement, leading to inefficient current flow and heat generation issues.
Innovation Solution
A connection member with bent portions is used, which is formed by punching a substrate and includes extension portions to absorb and disperse stresses in three-dimensional directions, allowing efficient connection and disconnection of storage elements during vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse is thinned to easily absorb displacement due to vibration, then the displacement can be easily absorbed, but the current amount to flow is decreased, which causes an increase in heat generation and restrains the allowable current amount
Solution Approach 1:
The connecting portion is divided into multiple bent portions (first bent portion and second bent portion) that are bent in different directions perpendicular to the punching direction. This segmentation allows each bent portion to independently absorb displacement in specific directions, providing multi-directional stress absorption capability while maintaining sufficient current flow cross-sectional area to reduce heat generation.
Solution Approach 2:
The connecting portion utilizes three-dimensional bending in multiple directions (first direction and second direction perpendicular to punching direction) to absorb displacement stresses. By adding dimensional complexity to the bending structure, the invention enables the fuse to absorb displacement in multiple axes without thinning the cross-sectional area, thereby maintaining current flow capability while improving displacement absorption.
2Loss of energy
If the fuse is made large to increase current amount to flow, then the heat generation and restraint of allowable current amount are relaxed, but the displacement due to vibration is hard to be absorbed
Solution Approach 1:
The connecting portion is segmented into multiple bent portions with different bending directions. This segmentation allows the structure to maintain a larger overall cross-sectional area for current flow while distributing displacement absorption across multiple oriented bent portions, resolving the contradiction between size for current flow and flexibility for displacement absorption.
Solution Approach 2:
Different portions of the connecting portion have different local geometries - the bent portions are designed with specific curvature and orientation to absorb displacement in particular directions, while the main body maintains sufficient cross-sectional area for current flow. This local differentiation allows simultaneous optimization of both current flow and displacement absorption.
3Reliability
If separate fuses and bus bars are provided to enable fusing characteristic, then the current limiter function is achieved, but it is hard to secure a contact point that allows assembly tolerance and vibration displacement
Solution Approach 1:
The fuse and bus bar are merged into a single integrated connecting portion formed by punching and bending a substrate. This merging eliminates the need for separate components and their associated assembly tolerances, while the bent portions provide the necessary flexibility to accommodate vibration displacement and assembly variations.
Solution Approach 2:
The connecting portion serves multiple functions simultaneously: it acts as a current limiter through its fusing characteristic, provides mechanical connection between storage elements, and absorbs displacement through its bent portions. This multi-functionality replaces the need for separate specialized components, improving both current limiting reliability and assembly tolerance.
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 connection member effectively absorbs and disperses stresses caused by vibration, maintaining efficient current flow while reducing heat generation and improving the assembly's tolerance to displacement.
Implementation Method 1
the at least two bent portions are bent along the first direction and the second direction perpendicular to the punching direction and perpendicular to each other. On this account, stresses to act in respective directions perpendicular to the punching direction are absorbed/dispersed by bending displacements of respective bent portions
Implementation Method 2
when the fuse is thinned, the displacement due to vibration or the like can be easily absorbed, but a current amount to flow is decreased, which causes an increase in an amount of heat generation
Data Source
AI summary
A connection member configured to electrically connect respective storage elements to each other in a power storage device constituted by a plurality of storage elements. The connection member includes: a substrate; and a plurality of connecting portions connected to electrodes of the respective storage elements and configured to cut off electric connection with the storage elements by fusing at the time when a current of a predetermined value or more flows therein. The connecting portion is formed by performing punching on the substrate and includes at least two bent portions bent in a punching direction. One of the bent portions is bent along a first direction perpendicular to the punching direction, and the other one of the bent portions is bent along a second direction perpendicular to the punching direction and perpendicular to the first direction.