Flexible Battery Terminal for PCB Misalignment and Vibration
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Solution Overview
Problem
Existing battery-to-PCB connections in electric vehicles are rigid, leading to alignment issues due to mechanical tolerances and vibrations, which can disrupt the reliability of electrical connections and voltage monitoring in lithium-ion battery cells.
Innovation Solution
A flexible battery terminal with an elongated mounting hole and double bend bifurcated solder terminals that can deflect and articulate to accommodate misalignments, allowing for secure connections to be maintained despite mechanical displacements and vibrations, using materials like thin flexible metal alloys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid direct connection is used between PCB and battery cell terminals, then the connection structure is simple and easy to manufacture, but the connection reliability deteriorates due to misalignment from mechanical tolerances and vibrations
Solution Approach 1:
The battery terminal incorporates a flexible bridge element that can dynamically adjust its position and orientation to accommodate misalignments between PCB mounting holes and battery cell terminals. The flexible bridge acts as a compliant mechanism that absorbs positional deviations and maintains reliable electrical connection despite vibrations and thermal expansions during vehicle operation.
Solution Approach 2:
The flexible bridge is constructed from thin flexible metal alloy that can bend and deflect to compensate for alignment errors. This thin flexible structure allows the terminal to adapt to positional variations while maintaining mechanical strength and electrical conductivity, resolving the contradiction between connection reliability and structural simplicity.
2Adaptability or versatility
If a flexible terminal with articulation capability is used, then the tolerance for mechanical displacements is improved, but the manufacturing complexity increases
Solution Approach 1:
The battery terminal is segmented into distinct functional parts: a rigid mounting portion attached to the battery cell terminal, a flexible bridge element with articulation capability, and a connection portion attached to the PCB. This segmentation allows each part to be optimized independently for its specific function while simplifying the overall manufacturing process through modular assembly.
Solution Approach 2:
The flexible bridge's geometric parameters (thickness, length, bend radius) are specifically designed to provide the required articulation range while maintaining manufacturability. By carefully controlling these parameters, the terminal achieves high alignment tolerance through material properties and geometry rather than complex mechanical mechanisms, keeping manufacturing relatively simple.
3Reliability
If the PCB is directly rigidly mounted to battery cells, then the assembly process is simple, but the system cannot withstand vibrations and thermal expansions
Solution Approach 1:
The flexible bridge serves as an intermediary element between the rigid battery cell terminal and the PCB mounting structure. It mediates the mechanical stresses from vibrations and thermal expansions, absorbing these forces through its flexibility while maintaining stable electrical connection. This intermediary approach protects both the PCB and battery cells from damaging forces.
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 battery terminal ensures a stable and reliable connection between the battery cells and PCB, preventing undue force on components and maintaining connectivity through thermal expansion and vibration, thereby enhancing the tolerance for mechanical and thermal variations.
Implementation Method 1
the flexible battery terminal is shaped such that it holds the screw by mechanical compliance and lines up with each threaded hole or terminal pad in an array of mounted battery cells, regardless of any slight misalignment of cells
Implementation Method 2
permit connection between the battery and the PCB to continue even when mechanical displacements occur during service life of the battery that, for example, might be due to vibration and/or thermal expansion of the cells and support structures
Data Source
AI summary
A flexible battery terminal for an electric vehicle is provided that permits a greater range of permissible connection orientations between, for example, a PCB and a battery cell.