Battery Overcharge Detection via Grounded Mounting Frame
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Solution Overview
Problem
Lithium secondary cells in battery packs are prone to overcharging, leading to swelling, fire risks, and toxic gas emission, with existing solutions causing damage to the battery pack and rendering it useless.
Innovation Solution
An apparatus comprising a battery module with a voltage sensor and a conductor mounting frame that grounds the module, allowing the battery controller to detect overcharging by sensing voltage changes and prevent further charging, thereby minimizing swelling and gas emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery cell cover is deformed to cut off power when the battery swells due to overcharging, then overcharging is prevented, but terminal parts are broken rendering the battery pack useless
Solution Approach 1:
A conductive mounting frame is introduced as an intermediary component between the battery module and the ground. When the battery swells due to overcharging, the battery module contacts the mounting frame which provides a safe discharge path for electricity, preventing terminal damage while still stopping the charging process through voltage sensing
2Reliability
If the battery cell cover is deformed to cut off power when the battery swells, then overcharging is prevented, but toxic gas is exhausted during the swelling process
Solution Approach 1:
The system performs preliminary detection of overcharging conditions through voltage sensing before significant swelling occurs. The battery controller detects abnormal voltage levels and stops charging in advance, preventing the battery from reaching the severe swelling stage that would generate toxic gas
3Power
If lithium secondary cells are used to provide higher output compared to capacity, then power density is improved, but stability decreases leading to overcharging risks
Solution Approach 1:
A battery controller with voltage sensing capability continuously monitors the battery voltage and provides feedback control. When overcharging conditions are detected through abnormal voltage levels, the controller automatically stops the charging process, providing a closed-loop safety mechanism that maintains stability while allowing high power output
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 apparatus effectively reduces battery pack swelling and damage while preventing toxic gas release during overcharging, ensuring safety and maintaining the battery pack's functionality.
Implementation Method 1
a battery controller connected to the battery module, the battery controller having a voltage sensor
Implementation Method 2
a ground connected to the mounting frame to ground the mounting frame
Data Source
AI summary
Disclosed is an apparatus for preventing a battery from overcharging. In particular, the apparatus includes a battery module which has a plurality of battery cells and a battery controller that is connected to the battery module. The battery controller has a voltage sensor. A mounting frame is arranged a predetermined distance from the battery module, and is made of a conductor to which a ground is connected. The battery controller determines that overcharging to the battery module has occurred when the voltage sensor senses a low voltage due to the battery module coming in contact with the mounting frame because of swelling.