Battery Lead-Out Plate Sizing for Thermal Safety

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Solution Overview

Problem

Existing battery designs face issues with thermal safety due to lead-out plates having either excessive or insufficient cross-sectional areas, leading to resource waste or heating problems.

Innovation Solution

The battery design incorporates lead-out plates with a specific cross-sectional area to capacity ratio (0<C/slead≤15) to ensure effective current carrying capability without excessive temperature rise, using orthogonal cross-sectional areas for positive and negative plates and conductive posts made of aluminum and copper.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the cross-sectional area of the lead-out plate is increased, then the current carrying capability is improved, but the resource utilization deteriorates

Engineering Contradiction:

Improvecurrent carrying capabilityVSAvoidresource waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent applies parameter changes by establishing a specific quantitative relationship between the cross-sectional area of the lead-out plate (Slead) and the battery capacity (C), defined as 0 < C/Slead ≤ 15. This parameter optimization ensures the lead-out plate has sufficient current carrying capability while avoiding excessive material usage, thereby resolving the contradiction between reliability and resource utilization.

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If the cross-sectional area of the lead-out plate is decreased, then the resource utilization is improved, but the temperature rise increases

Engineering Contradiction:

Improveresource utilizationVSAvoidtemperature rise

Core Design Contradiction:

Loss of substanceVSTemperature

Solution Approach 1:

The patent resolves this contradiction by optimizing the parameter relationship 0 < C/Slead ≤ 15, which determines the minimum required cross-sectional area of the lead-out plate. This optimized parameter ensures the plate is not overly large (avoiding resource waste) while maintaining sufficient area to prevent excessive temperature rise during operation, thus balancing resource utilization with thermal performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent incorporates feedback mechanisms through temperature monitoring and management systems that adjust operational parameters based on real-time temperature conditions. This feedback ensures that even with an optimized (not maximized) lead-out plate area, the temperature remains within safe operating ranges, preventing thermal safety issues while maintaining resource efficiency.

Inventive Principle:

Principle #23Feedback

3Reliability

If the cross-sectional area of the lead-out plate is increased, then the current carrying capability is improved, but the thermal safety deteriorates

Engineering Contradiction:

Improvecurrent carrying capabilityVSAvoidthermal safety

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent resolves this contradiction by establishing the optimized parameter relationship 0 < C/Slead ≤ 15. This parameter optimization prevents the lead-out plate from being excessively large, which could cause overheating and thermal safety issues. The optimized area ensures sufficient current carrying capability while maintaining thermal safety through appropriate heat dissipation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the potential harm of excessive current carrying capacity (which could lead to overheating) into a benefit by optimizing the lead-out plate area to the appropriate range. This optimization ensures that the current carrying capability is sufficient for safe operation without being excessive, thereby converting what could be a thermal hazard into a safe and efficient design.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

This configuration enhances thermal safety by maintaining internal temperatures within the operating range, reducing the risk of thermal issues and optimizing resource utilization.

Implementation Method 1

a lead-out plate is arranged in a battery housing and is connected between tabs of an electrode core and a conductive post, so that a current flows inside and outside the battery

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

a cross-sectional area of the lead-out plate is too small, resulting in a heating problem, and further causing a thermal safety problem of the battery

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20250023206A1Battery, battery pack, and vehicle

Publication Date: 2025.01.16 BYD CO LTD

AI summary

A battery includes a battery housing, an electrode core, lead-out plates, and conductive posts. The electrode core and the lead-out plates are connected to each other and disposed in the battery housing, and the conductive posts pass through the battery housing to connect to the lead-out plates. A relationship between a cross-sectional area slead in mm2 of the lead-out plates and a capacity C in Ah of the battery is 0<C/slead≤15.