Battery Overcharge Protection via Anode Tab Melting
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Solution Overview
Problem
Conventional battery overcharge prevention methods are complex and costly, requiring multiple components and a control unit, which complicates the configuration and increases manufacturing costs, and do not effectively prevent overcharge without adding a function to the control unit using only passive elements.
Innovation Solution
A battery overcharge prevention apparatus using a voltage division unit and a switching unit connected to the anode and cathode tabs of a battery, where the switching unit is closed at an overvoltage, causing an overcurrent that breaks down the anode tab, isolating the battery from the charging power source, and is made of a conductive material that melts at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a relay is used to block overcharge current, then overcharge prevention is achieved, but the relay may short and fail to turn off, making overcharge prevention impossible
Solution Approach 1:
The patent employs a fuse as a disposable protective element that intentionally fails in a controlled manner. When overcharge occurs, the fuse melts and opens the circuit, providing reliable overcharge protection. The fuse is designed to sacrifice itself (short-living) to protect the battery, eliminating the reliability issues associated with reusable relays that may short and fail to open.
2Measurement precision
If multiple components such as pole plates, resistors, and control units are added for overcharge detection, then overcharge detection capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the overcharge protection function from complex control systems and implements it through a simple, dedicated fuse-based mechanism. Instead of using multiple components like pole plates, resistors, and control units, the invention isolates the critical protection function to a single fuse element that automatically responds to overcharge conditions, dramatically reducing device complexity while maintaining detection capability.
Solution Approach 2:
The fuse provides self-service overcharge protection by automatically melting and opening the circuit when overcharge voltage is reached, without requiring external control units, sensing circuits, or active components. The fuse inherently detects and responds to overcharge conditions through its own physical properties, eliminating the need for additional measurement and control components.
3Reliability
If active control units and sensing circuits are used for overcharge protection, then protection functionality is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive active control units and sensing circuits with an inexpensive passive fuse element. The fuse provides reliable overcharge protection functionality at a fraction of the cost of electronic control systems, making the protection mechanism economically viable for mass production while maintaining safety effectiveness.
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 solution provides a simple, cost-effective way to prevent battery overcharge by blocking voltage to the battery module, enhancing safety by isolating the battery from the charging power source and preventing explosions or ignitions due to overcharge, without requiring additional functions in the control unit.
Implementation Method 1
the anode tab is made of a conductive material that is melted and broken down due to an increase in temperature attributable to the overcurrent occurring when the battery is shorted
Data Source
AI summary
An apparatus for preventing battery overcharge according to the present invention comprises: a voltage division unit having one end connected to a positive tap of a battery and the other end connected to a negative tap of the battery; and a switching unit having one end connected to the positive tap and the other end connected to the negative tap, the switching unit being shorted or opened according to a voltage divided from the voltage division unit. When a voltage between the positive tap and the negative tap is larger than or equal to a first voltage, the switching unit is shorted, the battery is shorted, an overcurrent is generated, the positive tap is destroyed, and the battery is electrically separated from a charging power source. The apparatus uses only passive devices, which makes it unnecessary to add a function for preventing an overcharge to a control unit, and has a simple construction enough to be added to a sensing circuit of a battery cell. When the overcharge is generated, the battery can be further secured by blocking a voltage applied to the battery cell within a battery module, and the overcharge can be prevented by detecting an overvoltage. Further, when the overvoltage is generated due to the detection of an unexpected battery voltage or an inevitable condition, it is possible to prevent the battery from reaching a dangerous state by blocking the voltage applied to the battery.