Cylindrical Battery Connector Layout for Fast Overcurrent Isolation
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Solution Overview
Problem
Existing battery modules face issues with overheating and safety risks due to overloaded currents, leading to reduced service life and efficiency, with current-limiting structures being less sensitive and causing significant losses.
Innovation Solution
A connector for large cylindrical batteries with current-limiting regions and through holes, designed to quickly disconnect circuits during short circuits or overloads, using low-melting-point metals and thin regions to fuse and cut current loops, enhancing safety and reducing thermal runaway risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a current-limiting connector is arranged in the battery module to protect against overloaded current, then circuit protection is improved, but the protection is less sensitive and causes large losses because only some batteries are protected
Solution Approach 1:
The connector is divided into multiple independent current-limiting regions (first current-limiting region and second current-limiting region), each capable of independently fusing to disconnect specific battery connections. This segmentation allows individual battery protection rather than protecting only some batteries, thereby reducing energy loss from overload more effectively.
Solution Approach 2:
Different regions of the connector are designed with different current-limiting capabilities. The first current-limiting region connects positive electrodes of adjacent batteries, while the second current-limiting region connects negative electrodes. This local differentiation ensures comprehensive protection across all batteries in the module.
2Object-affected harmful factors
If the connection area between positive-electrode connecting region and negative-electrode connecting region is reduced through the first through hole, then thermal runaway risk is reduced, but the connector structure becomes more complex
Solution Approach 1:
The connector structure is segmented with through holes creating distinct isolated regions. The first through hole separates the positive-electrode connecting region from the negative-electrode connecting region, preventing thermal propagation while maintaining electrical connectivity through dedicated current-limiting paths.
Solution Approach 2:
The current-limiting regions act as intermediary elements between positive and negative electrode connections. These regions provide controlled thermal and electrical isolation, allowing the connector to manage heat flow and current distribution without direct contact between opposing electrode regions.
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 connector effectively protects the battery circuit from overheating, reduces thermal runaway losses, and facilitates quick identification and maintenance of damaged batteries, improving safety and service life.
Implementation Method 1
the first current-limiting region and the second current-limiting region may be fused due to concentrated thermal stresses
Implementation Method 2
When the large cylindrical battery pack has a short circuit or overloaded current, the temperature in the circuit may be excessively high
Data Source
Figure 1~2
Figure 3
AI summary
The present application relates to the technical field of batteries and discloses a connector for a large cylindrical battery, a battery module, and a battery pack. The connector for the large cylindrical battery is configured for a large cylindrical battery having a positive electrode and a negative electrode on a same side, and includes a plurality of conductive units (100). Each conductive unit (100) includes a positive-electrode connecting region (110), a negative-electrode connecting region (120), and a first current-limiting region (130) provided between the positive-electrode connecting region (110) and the negative-electrode connecting region (120). Adjacent conductive units (100) are electrically connected to each other via a connection member (200).