Large Cylindrical Battery Connector With Localized Overload Fusing
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Solution Overview
Problem
Existing battery modules face issues with high current overload leading to excessive temperature, potential burning, and reduced service life, with current-limiting connectors only partially protecting batteries and being less sensitive.
Innovation Solution
A connector for large cylindrical batteries featuring conductive units with first and second current-limiting regions, connected by a member with lower fusing temperatures, designed to quickly cut current in case of overload, enhancing safety and service life by protecting all batteries in the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a current-limiting connector is arranged in the battery module to protect against overload, then circuit protection is improved, but only some batteries are protected and the structure is less sensitive causing large losses
Solution Approach 1:
The connector is divided into multiple conductive units, each with its own current-limiting region. This segmentation allows each unit to independently protect individual batteries, ensuring that when one battery is overloaded, only that specific unit disconnects while others remain operational, thereby reducing overall energy loss and improving protection coverage.
Solution Approach 2:
Each conductive unit is equipped with localized current-limiting regions at critical positions (positive-electrode connecting region, negative-electrode connecting region, and connecting member). This local quality enhancement ensures that protection is applied precisely where needed, making the structure more sensitive to local overload conditions and enabling faster, more accurate disconnection responses.
2Power
If batteries are connected in series or parallel to increase output voltage or current, then power output is improved, but the current may be overloaded causing excessive temperature and reduced service life
Solution Approach 1:
The connector acts as an intermediary device between batteries connected in series or parallel. It includes current-limiting regions with lower fusing temperatures than the connecting members, serving as a sacrificial protective element that disconnects the circuit when overload causes excessive temperature, thereby protecting the batteries and circuit from thermal damage while allowing high power output operation.
3Reliability
If a current-limiting connector is used to disconnect the circuit during overload, then circuit protection is improved, but the structure is less sensitive and only protects some batteries
Solution Approach 1:
The connector is divided into multiple conductive units with separate current-limiting regions, enabling independent detection and protection for each battery connection point. This segmentation increases detection sensitivity by allowing localized monitoring of current and temperature conditions at each unit, ensuring that overload events are detected and responded to more accurately and comprehensively across all batteries.
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 reduces losses and improves safety by quickly disconnecting current in case of overload, identifying and isolating damaged batteries, and reducing maintenance costs.
Implementation Method 1
a fusing temperature of the first current-limiting region is lower than a fusing temperature of the positive-electrode connecting region or a fusing temperature of the negative-electrode connecting region, and a fusing temperature of the second current-limiting region is lower than a fusing temperature of the connecting member
Data Source
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. Each conductive unit includes a positive-electrode connecting region, a negative-electrode connecting region, and a first current-limiting region provided between the positive-electrode connecting region and the negative-electrode connecting region. Adjacent conductive units are electrically connected to each other via a connection member.