Views: 0 Author: Site Editor Publish Time: 2026-02-03 Origin: Site
In the real-world operation of E-Scooters, E-Rickshaws, and heavy-duty engineering machinery, the biggest enemy of a battery pack is often not the chemical aging of charge cycles, but constant mechanical vibration.
Many battery manufacturers have faced this aftermarket nightmare: a battery pack that performs perfectly at the factory suddenly loses power after months of driving on rough roads. Teardown analysis reveals that the cells are fine; instead, the nickel tabs used for interconnection have suffered Fatigue Fracture due to thousands of micro-vibrations, or spot welds have detached due to stress concentration.
To tackle the challenge of harsh road conditions, we analyze how to achieve "Off-Road Grade" connection reliability through dual optimization of structural design and material processing.
When a battery pack is subjected to impact, rigid interconnects are often forced to withstand immense pulling forces. If this stress has nowhere to go, it attacks the weakest link in the entire system—the spot weld.
Introducing Stress Relief Slits technology into precision stamping die design is key to solving this issue:
Structural Decoupling: We design special "S-shape," "V-shape," or wave-like cutouts in the bridge section connecting the positive and negative terminals.
Flexible Buffering: This gives the originally rigid nickel tab micro-elastic deformation capabilities. When the battery holder twists or shifts due to bumps, the tab absorbs the energy like a spring, rather than rigidly transmitting the force to tear off the weld.
Material selection is a balancing act. Nickel tabs that are too soft cannot be picked up by automated vacuum nozzles, while those that are too hard are brittle and have poor fatigue resistance.
Unlike generic off-the-shelf products, vibration-resistant interconnects require the use of nickel strips processed with a Specific Temper. By strictly controlling the annealing temperature, we lock the Vickers Hardness (HV) within a narrow window optimized for vibration resistance. This material maintains enough mechanical strength to support busbar structures while possessing excellent Elongation, exhibiting a "tough-but-yielding" characteristic in ultimate tensile tests rather than snapping brittly.
Another common cause of vibration-induced detachment is that the initial weld was never secure. Especially in cylindrical cell assembly, micro-burrs or shearing deformation on the edge of the nickel tab can cause poor contact (floating) between the welding needle and the battery surface.
3D Chamfering: We use special stamping dies to micro-chamfer the edges of the nickel tabs. This ensures they fit perfectly into the slots of the battery holder without any lifting, guaranteeing an absolutely flat welding surface.
Preset Dimples (Projection Points): For difficult welding scenarios, we can pre-stamp precision dimples onto the nickel tab. These guide the welding current to concentrate at specific points, creating a deeper weld nugget and increasing Pull Force by over 30%, fundamentally eliminating the risk of "false welds."
A true anti-vibration solution cannot just exist on blueprints; it must pass rigorous physical validation. Qualified vibration-resistant interconnects should undergo tests that simulate real road conditions:
Vibration Table Testing: Long-cycle random vibration testing based on SAE J2380 or similar road vibration standards.
Drop Testing: Ensuring internal connections remain intact even during accidental impact drops.
