Battery Pole Weak Section for Overload and Overheat Breakage

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Solution Overview

Problem

Existing battery safeguarding structures, such as fuses, often result in safety risks due to high-temperature molten globules and lack of high-temperature protection, especially when subjected to overload currents or external high temperatures.

Innovation Solution

A pole for batteries featuring a weak section with a lower cross-sectional area and an expansion material that expands at elevated temperatures, allowing for electrical fusing and breakage protection against both overload currents and overheating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fuse safeguarding structure is used in the connecting piece, then overload current protection is achieved, but high-temperature molten globules may drop to the pole group reducing safety

Engineering Contradiction:

Improveoverload current protectionVSAvoidhigh-temperature molten globule drop

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention extracts the safeguarding function from the connecting piece and relocates it to the pole body. The weak section in the pole body serves as the new safeguarding structure, separating the fusing function from the connecting piece and preventing molten globule formation in the connecting piece area.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The weak section acts as an intermediary safeguarding structure between the connecting piece and the pole group. When fusing occurs, it happens in the weak section rather than the connecting piece, and the insulator positioned above the weak section serves as a mediator to contain and guide the molten globule away from the pole group.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If traditional battery structure without high-temperature protection is used, then device simplicity is maintained, but safety risk increases during thermal runaway or high external temperature

Engineering Contradiction:

Improvestructure simplicityVSAvoidhigh-temperature safety

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The invention changes the physical parameter of the expansion material by selecting materials with specific thermal expansion properties. The expansion material is chosen to expand at temperatures between 50-150°C, creating a temperature-responsive safety mechanism that activates before thermal runaway occurs.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention utilizes phase transition of the expansion material from solid to expanded state at elevated temperatures. This phase change causes the expansion material to expand and break the pole body at the weak section, providing automatic high-temperature protection without complex control systems.

Inventive Principle:

Principle #36Phase transitions

3Reliability

If expansion material is added to the weak section, then high-temperature breakage protection is achieved, but manufacturing process complexity increases

Engineering Contradiction:

Improvehigh-temperature breakage protectionVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The expansion material is pre-filled into the weak section during the pole body manufacturing process. The insulator is designed with a filling hole that allows the expansion material to be inserted before the pole body is completely assembled, enabling the safety feature to be integrated into the manufacturing flow rather than added as a separate post-processing step.

Inventive Principle:

Principle #10Preliminary action

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 damage by electrically fusing at the weak section under overload and breaking at high temperatures, enhancing safety by preventing overheating and molten globule drop, thus ensuring comprehensive protection against both overload and thermal runaway.

Implementation Method 1

an expansion material arranged in the weak section, and configured to expand when an ambient temperature or a temperature of the pole body is higher than a set temperature

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

a cross-sectional area of the pole body having a lower limit value at the weak section to allow the pole body to be electrically fused at the weak section when an overload current flows through the pole body

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20250007130A1Pole and Battery

Publication Date: 2025.01.02 コーネックスニューエナジーカンパニーリミテッド

AI summary

A pole includes a pole body and an expansion material. The pole body includes a weak section, a cross-sectional area of the pole body has a lower limit value at the weak section to allow the pole body to be electrically fused at the weak section when an overload current flows through the pole body. The expansion material is arranged in the weak section, and configured to expand when an ambient temperature or a temperature of the pole body is higher than a set temperature, to allow the pole body to be broken at the weak section and to realize a breakage protection.