Battery connecting line structure

Abstract

The invention discloses a battery connecting line structure which comprises a plurality of batteries, a battery connecting line is sequentially connected with positive and negative electrodes of adjacent batteries and connected in series to form a battery pack, the battery connecting line comprises a fixed connecting terminal, a movable trigger terminal and an adjacent terminal, and the fixed connecting terminal is connected with the movable trigger terminal through a wire. The fixed connecting terminal is connected with the adjacent terminal through a wire, and the movable trigger terminal comprises an insulating sleeve arranged on a connecting column of the battery in a sleeving mode, a movable contact block movably arranged on the periphery of the insulating sleeve in a sleeving mode, a spring located between the insulating sleeve and the movable contact block, and an elastic air bag arranged in a mounting cavity in the bottom of the movable contact block. The elastic airbag is connected with the control air pipe. According to the battery connecting line structure, on one hand, the interference of partial faulty batteries is effectively avoided, on the other hand, the total discharge time of the battery pack is prolonged, and the reliability, available capacity and service life of the battery pack are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of battery connection technology, and more particularly to a battery connection structure. Background Technology

[0002] In various electrical devices and energy storage systems, to meet the demands of higher voltage or larger capacity, multiple individual batteries are typically connected in series, parallel, or a combination of both to form battery packs. Among these, series connection is the most common way to increase the operating voltage. However, series-connected battery packs have an inherent problem that seriously affects their overall performance and reliability, namely the "weakest link effect" or "limited capacity effect."

[0003] In a series circuit, the current flowing through each cell is strictly equal. The total usable capacity of the battery pack is limited by the cell with the smallest capacity, the total voltage is the sum of the voltages of all individual cells, and the operating state is dominated by the worst-performing cell. In actual use, due to slight differences in manufacturing processes, uneven operating environments, or different rates of individual aging, individual cells in the battery pack may fail first. Common failure modes include, but are not limited to: abnormally increased internal resistance, accelerated capacity decay, and micro-short circuits.

[0004] Once a battery cell experiences this type of failure, its negative impact can rapidly spread throughout the entire battery pack via series connections. During the charging phase, the faulty battery (especially those with capacity decay or micro-short circuits) will reach the charging cutoff voltage first, triggering the battery management system's (BMS) protection mechanism and forcing the charging process to terminate prematurely. This prevents other normal batteries from being fully charged, resulting in a decrease in overall usable capacity. During the discharging phase, the voltage of the faulty battery (especially those with dramatically increased internal resistance) will drop sharply, thereby lowering the overall output voltage of the battery pack. This may prematurely trigger undervoltage protection, shortening equipment uptime, or even causing sudden power outages under load. Furthermore, the abnormal state of the faulty battery (such as a micro-short circuit) may continue to consume energy from other batteries, exacerbating inconsistencies and potentially causing overheating and other safety hazards, accelerating the aging and failure of the entire battery pack.

[0005] Currently, traditional battery pack series connection schemes mainly rely on fixed metal connecting pieces (such as nickel plates or copper busbars) or wires to physically and permanently connect the battery electrodes together through welding, bolting, or other methods. Once this rigid connection is completed, the individual battery cells are bound together as an inseparable whole. Existing technology lacks a physical structure for automatically identifying and electrically isolating individual batteries that suddenly fail during battery pack operation. When a battery cell fails, it usually requires manual inspection, disassembly, and replacement of the faulty cell, a cumbersome process that is difficult to implement in many closed or integrated battery packs. Although some advanced battery management systems (BMS) can monitor and locate faulty batteries, their main function is to issue alarms or disconnect the entire battery pack's circuit; they cannot fundamentally "remove" the faulty cell from the series link to ensure that the remaining normal batteries continue to function.

[0006] Therefore, there is an urgent need for an innovative battery connection structure that not only enables electrical series connection between batteries but also has the ability to automatically or controllably isolate a single battery from the series circuit when a specific fault occurs in the individual cell. This effectively "removes" faulty batteries, freeing the overall performance of the battery pack from being limited by the worst individual cell, and significantly improving the reliability, usable capacity, and service life of the battery pack. This application is proposed based on this objective. Summary of the Invention

[0007] This invention addresses the shortcomings of existing technologies by providing a battery connection wire structure. This battery connection wire structure can prevent the performance degradation of one or more batteries in a battery pack, so that the entire battery pack is not limited by poor-performing batteries, and significantly improves the reliability, usable capacity and service life of the battery pack.

[0008] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a battery connection wire structure comprising a plurality of batteries, wherein the battery connection wire sequentially connects the positive and negative terminals of adjacent batteries in series to form a battery pack. The battery connection wire includes a fixed connection terminal, a movable trigger terminal, and an adjacent terminal. The fixed connection terminal and the movable trigger terminal are connected by a wire, and the fixed connection terminal and the adjacent terminal are connected by a wire. The movable trigger terminal includes an insulating sleeve sleeved on the connecting post of the battery, a movable contact block movably sleeved on the outer periphery of the insulating sleeve, a spring located between the insulating sleeve and the movable contact block, and an elastic airbag disposed in a mounting cavity at the bottom of the movable contact block. The elastic airbag is connected to a control air tube. The adjacent terminals are sequentially sleeved on the connecting posts of the batteries connected to the movable trigger terminals of adjacent battery connection wires. When the control air tube is inflated, the movable contact block is lifted by the elastic airbag and contacts the adjacent terminal to conduct electricity. When the control air tube is deflated, the movable contact block is pushed down by the spring and conducts electricity with the contact plate of the battery. This battery connection structure controls the expansion and contraction of the elastic airbag by controlling the inflation and deflation of the air tube, thereby controlling the lifting or lowering of the movable contact block. This allows the movable contact block to contact adjacent terminals or battery contacts, enabling the removal of some batteries from the series-connected battery pack as needed. By designing the total voltage of the series-connected battery pack to be greater than the actual operating voltage, during charging, several batteries are sequentially removed. Batteries that have reached the charging cutoff voltage are alternately removed to continue charging. This effectively avoids interference from some faulty batteries and ensures that all batteries are fully charged and the voltage is more balanced. During the discharging phase, the alternating removal of batteries maintains the total voltage. This effectively avoids interference from some faulty batteries and extends the total discharge time of the battery pack, significantly improving the reliability, usable capacity, and service life of the battery pack.

[0009] In the above technical solution, preferably, the top of the elastic airbag is fixed to the top of the mounting cavity, and a conductive sheet is provided at the bottom of the elastic airbag. The conductive sheet is connected to the movable contact block via a wire, an indicator light, and a resistor. With this structure, after the elastic airbag is inflated, the conductive sheet at the bottom of the elastic airbag becomes conductive with the battery contacts, allowing the rejected battery to power the indicator light. This makes it easy to observe the location of the disconnected battery from the outside. When the battery pack as a whole has performance problems, it is possible to determine which battery is faulty by observing which indicator lights are lit and functioning normally. This makes the detection more intuitive and facilitates repair and maintenance.

[0010] In the above technical solution, preferably, the indicator light is located outside the movable contact block.

[0011] In the above technical solution, preferably, the indicator light is located inside the movable contact block, and the movable contact block is provided with a light-transmitting hole for transmitting the light from the indicator light.

[0012] In the above technical solution, preferably, each of the control air pipes is equipped with a solenoid valve, the control air pipe is connected to a main air supply pipe, and the main air supply pipe is connected to an air pump. This structure allows for convenient control of the inflation and deflation of the elastic airbag by switching the solenoid valves on and off.

[0013] In the above technical solution, preferably, each of the control air tubes is connected to a venting micro-hole. This structure allows the elastic airbag to deflate automatically, and when the solenoid valve is connected to the control air tube, only inflation needs to be controlled, not deflation, making control more convenient.

[0014] Compared with existing technologies, this invention has the following advantages: This battery connection structure can control the expansion and contraction of the elastic airbag by controlling the inflation and deflation of the air tube, thereby controlling the lifting or lowering of the movable contact block, so that the movable contact block contacts the adjacent terminal or the battery contact piece. This allows for the removal of some batteries from the series-connected battery pack as needed. By designing the total voltage of the series-connected battery pack to be greater than the actual operating voltage, during the charging process, several batteries are removed sequentially. Batteries that have reached the charging cutoff voltage during the charging phase are also removed alternately to continue charging. This effectively avoids interference from some faulty batteries and ensures that each battery is fully charged and the voltage is more balanced. During the discharging phase, the method of alternately removing batteries maintains the total voltage. This effectively avoids interference from some faulty batteries and extends the total discharge time of the battery pack, significantly improving the reliability, usable capacity, and service life of the battery pack. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the battery connection wire in an embodiment of the present invention.

[0016] Figure 2 This is a partial cross-sectional view of the active trigger terminal in an embodiment of the present invention.

[0017] Figure 3 This is a cross-sectional view of the battery pack connection according to an embodiment of the present invention.

[0018] Figure 4 for Figure 3 A partial structural diagram of the deflated elastic airbag at point A.

[0019] Figure 5 for Figure 3 A partial structural diagram of the elastic airbag at point A in its inflated state. Detailed Implementation

[0020] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: See also Figures 1 to 5 A battery connection wire structure includes several batteries 1. Battery connection wires 2 connect the positive and negative terminals of adjacent batteries 1 in series to form a battery pack. The battery connection wires 2 include fixed connection terminals 3, movable trigger terminals 4, and adjacent terminals 5. The fixed connection terminals 3 and movable trigger terminals 4 are connected by wires, and the fixed connection terminals 3 and adjacent terminals 5 are connected by wires. The movable trigger terminal 4 includes an insulating sleeve 6 sleeved on the connecting post of the battery 1, a movable contact block 7 movably sleeved on the outer periphery of the insulating sleeve 6, a spring 8 located between the insulating sleeve 6 and the movable contact block 7, and an elastic airbag 10 disposed in the mounting cavity 9 at the bottom of the movable contact block 7. The elastic airbag 10 is connected to a control air tube 11. The adjacent terminals 5 are sequentially sleeved on the connecting posts of the batteries 1 connected to the movable trigger terminals 4 of the adjacent battery connection wires 2. When the control air tube 11 is inflated, the movable contact block 7 is lifted by the elastic airbag 10 and contacts the adjacent terminal 5 to conduct electricity. When the control air tube 11 is deflated, the movable contact block 7 is pushed down by the spring 8 and conducts electricity with the contact piece of the battery 1. This battery connection cable 2 structure can control the expansion and contraction of the elastic airbag 10 by controlling the inflation and deflation of the air pipe 11, thereby controlling the lifting or lowering of the movable contact block 7, so that the movable contact block 7 contacts the adjacent terminal 5 or the contact piece of the battery 1. This allows for the removal of some batteries 1 from the series-connected battery pack as needed. By designing the total voltage of the series-connected battery pack to be greater than the actual operating voltage, during the charging process, several batteries 1 are removed sequentially. Batteries 1 that have reached the charging cutoff voltage during the charging phase are also removed alternately to continue charging. This effectively avoids interference from some faulty batteries 1 and ensures that each battery 1 is fully charged and the voltage is more balanced. During the discharging phase, the method of alternately removing batteries 1 maintains the total voltage. This effectively avoids interference from some faulty batteries 1 and extends the total discharge time of the battery pack, significantly improving the reliability, usable capacity, and service life of the battery pack.

[0021] In this embodiment, the top of the elastic airbag 10 is fixedly connected to the top of the mounting cavity 9, and a conductive sheet 12 is fixedly installed at the bottom of the elastic airbag 10. The conductive sheet 12 is connected in series with the indicator light 13 and the resistor 14 via wires and then connected to the movable contact block 7. With this structure, after the elastic airbag 10 is inflated, the conductive sheet 12 at the bottom of the elastic airbag 10 is connected to the contact of the battery 1, and the rejected battery 1 can supply power to illuminate the indicator light 13. Since battery packs often have many batteries 1, this structure allows for clear observation of the location of the disconnected battery 1 from the outside, quickly locating the disconnected battery 1. When the battery pack as a whole has performance problems, it is possible to determine which battery 1 is faulty by observing which indicator lights 13 are lit and working normally, making the detection more intuitive and faster, thus facilitating inspection and maintenance.

[0022] In this embodiment, for ease of observation, the indicator light 13 is located outside the active contact block 7.

[0023] As will be readily understood by those skilled in the art, in other embodiments, the indicator light 13 may be located inside the movable contact 7, and the movable contact 7 may have a light-transmitting hole for the light from the indicator light 13 to pass through. This will not affect the observation of the light from the indicator light 13.

[0024] In this embodiment, each of the control air pipes 11 is equipped with a solenoid valve 15. The control air pipes 11 are connected to the main air supply pipe, which is connected to an air pump. This structure allows for convenient control of the inflation and deflation of the elastic airbag 10 by opening and closing the solenoid valves 15.

[0025] In this embodiment, several control air tubes 11 are connected to venting micro-holes 16. The diameter of the venting micro-holes 16 is typically 0.5-1 mm, and their venting speed should be less than the inflation speed of the air pump. This structure enables the elastic airbag 10 to deflate automatically. When the solenoid valve 15 is connected to the control air tubes 11, only inflation needs to be controlled, not deflation, making control more convenient.

[0026] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A battery connection wire structure, comprising a plurality of batteries (1), wherein battery connection wires (2) sequentially connect the positive and negative terminals of adjacent batteries (1) in series to form a battery pack, characterized in that: The battery connection cable (2) includes a fixed connection terminal (3), a movable trigger terminal (4), and an adjacent terminal (5). The fixed connection terminal (3) and the movable trigger terminal (4) are connected by a wire, and the fixed connection terminal (3) and the adjacent terminal (5) are connected by a wire. The movable trigger terminal (4) includes an insulating sleeve (6) sleeved on the connecting post of the battery (1), a movable contact (7) movably sleeved on the outer periphery of the insulating sleeve (6), a spring (8) located between the insulating sleeve (6) and the movable contact (7), and a spring (8) disposed on the movable contact. (7) The elastic airbag (10) in the mounting cavity (9) at the bottom is connected to the control air tube (11). The adjacent terminal (5) is sequentially sleeved on the connecting post of the battery (1) connected to the movable trigger terminal (4) of the adjacent battery connecting line (2). When the control air tube (11) is inflated, the movable contact (7) is lifted by the elastic airbag (10) and contacts the adjacent terminal (5) to conduct. When the control air tube (11) is deflated, the movable contact (7) is pushed down by the spring (8) and conducts with the contact piece of the battery (1).

2. The battery connection wire structure as described in claim 1, characterized in that: The top of the elastic airbag (10) is fixed to the top of the mounting cavity (9), and a conductive sheet (12) is provided at the bottom of the elastic airbag (10). The conductive sheet (12) is connected to the movable contact block (7) in series with the indicator light (13) and the resistor (14) through a wire.

3. The battery connection wire structure as described in claim 2, characterized in that: The indicator light (13) is located outside the active contact (7).

4. The battery connection wire structure as described in claim 2, characterized in that: The indicator light (13) is located inside the movable contact block (7), and the movable contact block (7) is provided with a light-transmitting hole for transmitting light from the indicator light (13).

5. The battery connection wire structure as described in claim 1, characterized in that: Each of the control air pipes (11) is equipped with a solenoid valve (15), the control air pipe (11) is connected to the main gas supply pipe, and the main gas supply pipe is connected to an air pump.

6. The battery connection wire structure as described in claim 1, characterized in that: Several of the control air tubes (11) are connected to venting micro-holes (16).

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