Battery Connector Arc Extinguishing Protective Component
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Solution Overview
Problem
Traditional battery connectors in electric vehicles lack an arc extinguishing mechanism, leading to safety risks of burning and explosion when fuses melt, and have structural weaknesses that reduce reliability due to the absence of a supporting shell.
Innovation Solution
A battery connector design featuring a fusing portion with a smaller cross-sectional area encased in a protective component, which includes a sealed chamber filled with hydrogen and magnetism members to extinguish electric arcs quickly and enhance structural support, preventing damage from electric arcs and improving connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional fuse device is used to connect battery modules, then the connection between battery modules can be severed timely when fault occurs, but an electric arc may generate when the fuse melts causing breakdown of the battery and risks of burning and explosion
Solution Approach 1:
The patent introduces a protective component as an intermediary structure that encases the fusing portion. This protective component includes arc extinguishing measures (such as arc extinguishing chambers or arc quenching materials) that intercept and extinguish electric arcs before they can damage the battery, thus resolving the contradiction between maintaining connection reliability and preventing arc-induced harm
Solution Approach 2:
The patent converts the harmful electric arc into a controlled phenomenon by designing arc extinguishing structures that guide and dissipate the arc energy safely. The arc energy is redirected into controlled paths within the protective component, transforming the potentially destructive arc into a contained event that does not compromise battery safety
2Device complexity
If a traditional fuse without supporting shell is used, then the structure is simple, but a crack may occur at the weakest portion of the fuse decreasing safety performance and reliability
Solution Approach 1:
The patent applies beforehand cushioning by introducing a protective component that provides structural support to the fusing portion before any failure occurs. This protective shell reinforces the weakest portions of the fuse structure, preventing cracks from initiating under stress, thus maintaining both structural simplicity and enhanced reliability
3Reliability
If the cross sectional area of the fusing portion is reduced, then the fusing portion can melt more easily to sever connection when fault occurs, but the structural strength of the connecting sheet may be decreased
Solution Approach 1:
The patent applies local quality by creating a fusing portion with reduced cross-sectional area only at the specific location where melting is needed, while the rest of the connecting sheet maintains its full structural strength. This localized thinning allows the fuse to respond quickly to faults without compromising the overall structural integrity of the connecting sheet
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 solution effectively prevents battery breakdown and explosion by quickly extinguishing electric arcs and enhancing the structural integrity of the connector, thereby ensuring safer and more reliable battery connections in electric vehicles.
Implementation Method 1
there is no arc extinguishing measure applied to the traditional fuse. When the fuse melts, an electric arc may generate, and the electric arc may breakdown the battery
Implementation Method 2
a first magnetism member and a second magnetism member respectively disposed at two opposite outer surfaces of the protective component
Data Source
Figure 1~2
Figure 3~4
AI summary
A battery connector for an electric vehicle is provided. The battery connector includes: a connecting sheet having a fusing portion, and a protective component in which the fusing portion is encased. A cross sectional area of the fusing portion is less than a cross sectional area of rest part of the connecting sheet.