Modular Battery Overcharge Preventer with Cutter Mechanism

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Solution Overview

Problem

Existing battery overcharge preventing devices in hybrid electric vehicles can damage battery cells and are complex, making them difficult to replace and potentially causing environmental pollution.

Innovation Solution

A battery module with an overcharge preventing device that includes a frame, bus bar, and a cutter mechanism, allowing the bus bar to be cut when the battery expands, thereby blocking power without damaging the battery cells, and is designed to be easily mounted and replaced.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a battery overcharge preventing device is mounted in the battery module, then overcharge prevention is achieved, but the battery cell is damaged when expanded causing poisonous gas discharge

Engineering Contradiction:

Improveovercharge preventionVSAvoidbattery cell damage and poisonous gas discharge

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The bus bar serves as an intermediary component that can be selectively cut to disconnect electrical connection between battery cells during overcharge conditions, preventing the need to damage the battery cell structure itself for overcharge protection

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The overcharge preventing device is designed as a separate replaceable module inserted between battery cells, segmenting the protection function from the battery cell structure, allowing the device to be replaced without damaging the battery cells

Inventive Principle:

Principle #1Segmentation

2Reliability

If a battery overcharge preventing device is mounted in the battery module, then overcharge prevention is achieved, but the structure becomes complex and difficult to replace

Engineering Contradiction:

Improveovercharge preventionVSAvoidmounting structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The overcharge preventing device is designed as a self-contained modular unit with frame, bus bar, and cutter mechanism that can be independently replaced without affecting other battery module components, simplifying the replacement process despite the internal complexity of the device

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame structure serves multiple functions: providing mechanical support, guiding the cutter mechanism, and facilitating easy installation and replacement of the entire overcharge preventing device as a single unit

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the bus bar is cut by battery expansion, then power blocking is achieved, but the battery cell expansion indicates overcharge condition

Engineering Contradiction:

Improvepower blocking capabilityVSAvoidbattery cell expansion from overcharge

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The battery cell expansion caused by overcharge, which is normally a harmful condition, is converted into a useful triggering mechanism that automatically cuts the bus bar through the cutter, blocking power and preventing further damage

Inventive Principle:

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

Solution Approach 2:

The cutter mechanism acts as an intermediary that translates the physical expansion of the battery cell into the electrical disconnection of the bus bar, converting mechanical expansion into an electrical protection action

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively prevents battery overcharge without damaging the cells and allows for easy replacement of the overcharge preventing device, enhancing safety and reducing environmental impact.

Implementation Method 1

the bus bar may be cut by expansion of the battery cell

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS9673644B2Battery module having overcharge preventing device, and overcharge preventing device for battery module

Publication Date: 2017.06.06 HYUNDAI MOBIS CO LTD

AI summary

The present invention relates to a battery module mounted with an overcharge preventing device, and an overcharge preventing device for a battery module. The battery module mounted with an overcharge preventing device of the present invention includes: a battery cell including a first battery cell and a second battery cell, which are spaced apart from each other; and an overcharge preventing device inserted and disposed between the first battery cell and the second battery cell, and configured to block power supplied to the battery cell when the battery cell is expanded according to overcharge, in which the overcharge preventing device is configured as one module separately from the battery cell, and is replaceably disposed between the first battery cell and the second battery cell, which are spaced apart from each other.