Battery Pack Terminal Structure for Ultrasonic Welding Vibration Isolation
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Solution Overview
Problem
Conventional secondary battery modules experience disconnection and damage of electric wires due to vibration loads during ultrasonic welding of voltage detection terminals and bus bars, as the structure only presses the connection portion perpendicularly, inadequately suppressing vibration loads.
Innovation Solution
A battery pack design featuring a voltage detection terminal with a first base portion bonded vertically to a bus bar, a second base portion connected to an electric wire, and a protrusion portion between them, which helps absorb and redirect vibration loads, preventing disconnection and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the voltage detection terminal uses a conventional shape without a protrusion portion, then the structure is simple, but the vibration load of ultrasonic welding directly propagates to the connection portion causing disconnection of the electric wire
Solution Approach 1:
The patent introduces a protrusion portion that extends in the ultrasonic vibration direction between the first base portion and second base portion. This dimensional addition creates a mechanical decoupling effect where the protrusion absorbs and redirects vibration loads, preventing direct transmission to the electric wire connection portion while maintaining overall structural simplicity
2Reliability
If the connection portion is pressed from a direction perpendicular to the vibration direction, then some suppression effect is achieved, but the suppression effect is small and disconnection still occurs
Solution Approach 1:
Instead of applying pressing force perpendicular to the vibration direction (one-dimensional approach), the patent introduces a protrusion portion that extends along the vibration direction. This creates a three-dimensional vibration isolation structure that effectively redirects vibration loads away from the connection portion, significantly reducing the harmful effects of ultrasonic welding vibrations
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 effectively prevents disconnection and damage of electric wires during ultrasonic welding by absorbing and redirecting vibration loads, enhancing the structural integrity of the connection between the voltage detection terminal and the electric wire.
Implementation Method 1
a first base portion that is located on one end side in a predetermined direction of the terminal and is bonded to the bus bar in a vertical direction with respect to the predetermined direction by ultrasonic welding
Data Source
AI summary
A battery pack has a plurality of batteries, a bus bar connected to electrode terminals of the plurality of batteries, a terminal connected to the bus bar, and an electric wire connected to the terminal. The terminal has a first base portion, a second base portion, and a protrusion portion. The first base portion is located on one end side in a predetermined direction of the terminal and is bonded to the bus bar in a vertical direction with respect to the predetermined direction by ultrasonic welding. The second base portion is located on the other end side in the predetermined direction of the terminal and is connected to the electric wire. The protrusion portion is located between the first base portion and the second base portion and protrudes in the vertical direction.