Battery Module Connector With Dielectric Overvoltage Blocking
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Solution Overview
Problem
Existing battery modules face safety risks from overvoltage, which can lead to ignition or explosion, and current safety technologies reduce energy density or cause thermal damage.
Innovation Solution
A connector with a dielectric layer having a dielectric constant between 2 and 50, made of materials like SiO2, ZrO2, and HfO2, is used to block current flow during overvoltage, maintaining energy density by preventing disconnection through Joule heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuse is used to block current during overvoltage, then safety is improved, but thermal damage is inflicted on surrounding components
Solution Approach 1:
The invention changes the material parameter of the connector by incorporating a dielectric material with a specific dielectric constant (2 < k < 50), which fundamentally alters how the connector responds to overvoltage. Instead of using a fuse that melts and causes thermal damage, the dielectric material blocks current through electrical insulation properties, preventing both overvoltage propagation and thermal damage to surrounding components.
Solution Approach 2:
The connector is constructed as a composite material combining conductive metal (for normal current conduction) and dielectric material (for overvoltage blocking). This composite structure enables the connector to perform dual functions: conducting current during normal operation and blocking current during overvoltage conditions without causing thermal damage, as the dielectric material does not melt like fuse material.
2Reliability
If a fuse is used to block current during overvoltage, then safety is improved, but energy density is reduced
Solution Approach 1:
The connector serves multiple functions: it conducts current during normal operation and blocks current during overvoltage conditions. By integrating the dielectric material directly into the connector structure, the safety function is built into the existing component rather than requiring separate fuse elements, thereby maintaining energy density while providing overvoltage protection.
Solution Approach 2:
By changing the material composition of the connector to include dielectric material with controlled dielectric constant, the connector inherently provides overvoltage blocking capability without requiring additional space for separate safety components, thus preserving the energy density of the battery module.
3Reliability
If the dielectric constant is increased to improve overvoltage blocking, then safety is improved, but the connector size must increase
Solution Approach 1:
The invention optimizes the dielectric constant parameter to a specific range (2 < k < 50) that provides effective overvoltage blocking capability while maintaining compact dimensions. This parameter optimization ensures that the connector achieves the required safety performance without unnecessary increase in volume, fitting within the constrained space of the battery module.
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 blocks current during overvoltage, ensuring safety without reducing energy density and allowing continuous use as a safety device.
Implementation Method 1
A connector with a dielectric layer having a dielectric constant between 2 and 50, made of materials like SiO2, ZrO2, and HfO2, is used to block current flow during overvoltage
Implementation Method 2
maintaining energy density by preventing disconnection through Joule heating
Data Source
Figure 1~2
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Figure 5~6
AI summary
The present invention relates to a connector and a battery module including the connector. The connector electrically connects members within a battery module to each other, the connector including one or more metals, and a dielectric. The dielectric has a dielectric constant (k) with an upper limit of 50 and a lower limit of 2.