Battery Module Sampling Leg Structure for Vibration and Expansion
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Solution Overview
Problem
The reliability of secondary battery voltage collection in battery modules is compromised due to the potential breakage of connection sheets caused by expansion and vibration of secondary batteries, which can lead to failure in the circuit board assembly's collection function.
Innovation Solution
A sampling assembly with a sampling leg that includes a first connection portion, an intermediate portion with deformability, and a second connection portion, where the intermediate portion has a smaller cross-sectional area to cushion tensile forces, reducing the likelihood of breakage and ensuring stable voltage collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circuit board assembly is used to collect voltage with a connection sheet connecting to busbar, then voltage collection function is achieved, but the connection sheet may break due to battery expansion and vibration, reducing reliability
Solution Approach 1:
The sampling leg incorporates a deformable intermediate portion that acts as a cushioning element before tensile forces can cause breakage. This intermediate portion with smaller cross-sectional area is designed to yield and absorb expansion and vibration forces, protecting the connection between the sampling circuit board and busbar from failure.
Solution Approach 2:
The sampling leg's cross-sectional area is varied along its length, with the intermediate portion having a smaller cross-sectional area than the connection portions. This parameter change creates a deliberate weak point that deforms under stress, absorbing tensile forces while maintaining electrical connectivity and preventing complete failure.
2Strength
If the connection sheet is made stronger to prevent breakage, then strength is improved, but it cannot accommodate battery expansion and vibration, reducing adaptability
Solution Approach 1:
The sampling leg is segmented into distinct functional portions: connection portions with larger cross-sectional area for strong electrical connection, and an intermediate portion with smaller cross-sectional area for deformation and cushioning. This segmentation allows different parts to serve different functions - maintaining strength where needed while providing flexibility where expansion occurs.
Solution Approach 2:
The sampling leg transitions from a static, rigid connection sheet to a dynamic structure where the intermediate portion can deform in response to battery expansion and vibration. This dynamic capability allows the connection to adapt to changing conditions while maintaining electrical connectivity, combining strength with flexibility.
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 sampling assembly effectively reduces the risk of breakage under tensile stress, enhancing the operational reliability and safety of battery modules by absorbing deformation and vibration-induced forces, thus maintaining normal collection functionality.
Implementation Method 1
an intermediate portion (62) having a deformability and a cushioning ability
Data Source
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AI summary
The application relates to a sampling assembly, a connection assembly, a battery module and a vehicle. The sampling assembly is used for a battery module including a busbar. The sampling assembly includes: a sampling circuit board having a predetermined length and a predetermined width; a sampling leg including a first connection portion, an intermediate portion and a second connection portion, the first connection portion being connected to the sampling circuit board, the second connection portion being used to be connected to the busbar, the first connection portion including a first connection region connected to the intermediate portion, the second connection portion including a second connection region connected to the intermediate portion, at least a part of the intermediate portion having a cross-sectional area which is smaller than a cross-sectional area of the first connection region and smaller than a cross-sectional area of the second connection region. The sampling assembly of the embodiments of the application can reduce the possibility of breaking of a sampling leg bearing a tensile force and improve its operational reliability.