Battery Lug Panel Assembly for Series-Cell Overcurrent Interruption
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Solution Overview
Problem
Existing overload protection devices do not effectively address overcurrent protection in commercial battery systems with multiple cells connected in series or parallel, and lack a rigid mechanism to maintain connection integrity during overcurrent events.
Innovation Solution
A non-conductive panel with battery lugs and mounting brackets, coupled with a power overload protector, forms an electrical path that breaks upon overcurrent, interrupting the connection between cells and maintaining cell alignment without electrical conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid panel structure is used to maintain cell connection stability, then connection integrity is improved, but the device complexity increases due to additional mounting brackets and structural components
Solution Approach 1:
The patent combines multiple functions into a single integrated panel structure that simultaneously provides electrical connection, mechanical support, and overcurrent protection. The panel integrates battery lugs, mounting brackets, and overload protector into one unified component, eliminating the need for separate structural elements while maintaining connection stability.
Solution Approach 2:
The panel serves multiple functions: it provides the electrical connection path between cells, maintains rigid structural support for cell alignment, enables mounting of the overload protector, and ensures stable connection during overcurrent events. This multi-functionality reduces overall device complexity while improving connection stability.
2Reliability
If a non-conductive panel is used to maintain structural integrity during overcurrent events, then safety is improved by preventing electrical conduction, but the manufacturing precision requirements increase for proper electrical path interruption
Solution Approach 1:
The non-conductive panel acts as an intermediary element between conductive components. It provides a controlled interruption point for electrical current while maintaining mechanical continuity. The panel's positioning and integration with mounting brackets ensure precise electrical path interruption without requiring high manufacturing precision, as the structural framework guides the electrical connection geometry.
3Reliability
If mounting brackets are added to couple the overload protector to battery lugs, then the overcurrent protection function is improved, but the device complexity and number of components increases
Solution Approach 1:
The mounting brackets are integrated directly into the panel structure rather than being separate components. The panel itself is designed with built-in mounting features that couple the overload protector to the battery lugs, eliminating the need for additional standalone mounting brackets and reducing overall device complexity while maintaining reliable overcurrent protection.
Data Source
AI summary
A commercial battery overcurrent protective device includes an elongated panel. The panel is comprised of a non-conductive material. Each of a pair of battery lugs is positioned adjacent to a respective one of opposite ends of the panel. Each of a pair of mounting brackets is coupled to an associated one of the pair of battery lugs. A power overload protector is coupled to and extends between the mounting brackets. The pair of battery lugs, the mounting brackets, and the power overload protector are electrically connected to define an electrical path. Each battery lug extends outwardly from the respective one of the opposite ends of the panel for coupling to a terminal of an associated cell of a pair of cells in series within a commercial battery. Thus, the power overload protector breaks the electrical path and interrupts electrical connection of the cells in series upon overcurrent within the commercial battery.