Vehicular Battery Module Variable Resistor Safety
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Solution Overview
Problem
Vehicular batteries can become unstable and potentially ignite or explode when overcharged due to gas and heat generation within the battery cell, necessitating a solution to induce self-discharge and prevent swelling.
Innovation Solution
A vehicular battery module with stacked battery cells, a variable-resistor, and a connecting bar that compresses to reduce resistance and induce self-discharge when a battery pouch swells, preventing overcharging-related issues by electrically connecting negative and positive electrode terminals and transferring swelling forces to the variable-resistor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a battery is charged beyond upper-limit voltage, then charging capacity is improved, but stability deteriorates due to gas and heat generation causing ignition or explosion
Solution Approach 1:
The variable resistor is pre-installed between electrode terminals in a dormant state. When swelling occurs due to overcharging, the resistor automatically activates to create a discharge path, preventing the harmful effects before they can develop into ignition or explosion.
Solution Approach 2:
The variable resistor acts as an intermediary component that mediates between the battery cells and the external environment. It provides a controlled discharge path that prevents direct short-circuiting while managing the release of excess energy, thereby maintaining system stability during overcharging events.
2Reliability
If battery pouch swells due to overcharging, then self-discharge is induced, but structural integrity deteriorates due to swelling force
Solution Approach 1:
The connecting bar serves as a mechanical intermediary that transfers the swelling force from the battery pouch to the variable resistor. This mediation allows the swelling energy to be utilized for activating the safety mechanism rather than causing direct structural damage to the battery pouch.
Solution Approach 2:
The swelling force, which is normally a harmful effect indicating battery damage, is converted into a beneficial trigger mechanism. The connecting bar captures this harmful swelling force and transforms it into the activation energy needed to rotate the dial and activate the variable resistor, turning a failure symptom into a safety feature.
3Reliability
If variable-resistor is compressed to reduce resistance value, then self-discharge is induced, but device complexity increases due to additional components
Solution Approach 1:
The connecting bar and dial mechanism are merged into a single integrated component that performs both mechanical support and rotational actuation functions. This consolidation reduces the number of separate parts needed while maintaining the self-discharge activation functionality.
Solution Approach 2:
The variable resistor serves multiple functions: it acts as a mechanical component that responds to swelling forces, an electrical component that controls resistance, and a safety device that induces self-discharge. This multi-functionality reduces the need for separate dedicated components for each function.
4Reliability
If connecting bar transfers swelling force to variable-resistor, then safety is improved, but manufacturing precision requirements increase
Solution Approach 1:
The safety mechanism is segmented into distinct functional zones: the connecting bar handles mechanical force transfer, the dial handles rotational actuation, and the variable resistor handles electrical resistance control. This segmentation allows each component to be manufactured and assembled independently with standardized tolerances, reducing overall manufacturing precision requirements.
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 solution ensures vehicle stability by inducing self-discharge, preventing swelling, ignition, and explosion of battery cells during overcharging, thereby enhancing safety and reliability.
Implementation Method 1
when the one-side battery pouch or the other-side battery pouch swells, the variable-resistor is compressed such that a resistance value thereof is decreased
Data Source
AI summary
A vehicular battery module that is capable of securing the stability of a vehicle by inducing self-discharge of a battery cell when the battery is overcharged includes: a plurality of stacked battery cells, each of which includes a battery pouch and electrode terminals extending outwards from the battery pouch, and a variable-resistor disposed between the electrode terminals of the one-side battery pouch and the other-side battery pouch so as to electrically connect the two electrode terminals to each other.