Cathodic Can Cap Assembly With Fuse for Corrosion and Short-Circuit Protection
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Solution Overview
Problem
Battery cells, particularly in high-powered applications like electric vehicles, face challenges in maintaining safety and durability due to corrosion and potential short circuits, especially when subjected to frequent charge and discharge cycles and excessive currents.
Innovation Solution
Incorporating a cathodic can with a safety fuse that operates in two modes: a first cathodic mode to inhibit corrosion by maintaining the can's potential above the negative terminal and a second abuse mode to disconnect in case of excessive current, thereby preventing short circuits and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the can is electrically connected to the positive terminal to maintain cathodic protection, then corrosion resistance is improved, but the risk of short circuits and safety hazards increases under excessive current conditions
Solution Approach 1:
A fuse is introduced as an intermediary component between the can and the positive terminal. This fuse normally conducts current to maintain cathodic protection of the can, but when excessive current occurs, the fuse blows and disconnects the connection, preventing short circuits. The fuse thus serves as a mediator that enables the beneficial cathodic protection while blocking harmful excessive currents.
2Object-affected harmful factors
If a fuse is added to disconnect under excessive current, then safety is improved, but device complexity increases
Solution Approach 1:
The fuse is integrated into the existing cap assembly structure rather than being a separate component. The cap assembly includes the terminal block, cap plate, insulating member, and fuse as a unified structure. This merging approach adds the safety function of the fuse without significantly increasing overall device complexity, as the fuse becomes part of the existing assembly rather than a standalone addition.
3Ease of manufacture
If the fuse is disposed in the insulating member, then manufacturing simplicity is improved, but insulation reliability may be compromised
Solution Approach 1:
The insulating member is designed with differentiated regions: an first region that provides electrical insulation between the terminal block and cap plate, and a second region that receives and accommodates the fuse. This local quality differentiation allows the insulating member to simultaneously provide insulation functionality and housing for the fuse, maintaining both insulation reliability and manufacturing simplicity through a single integrated component.
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 reduces corrosion and enhances safety by maintaining the can's cathodic protection and preventing short circuits, ensuring the longevity and reliability of battery cells.
Implementation Method 1
a first cathodic mode in which the fuse electrically connects the terminal block to the cap plate... The fuse is designed to be operated in the normal mode (a first cathodic mode) to electrically connect the terminal block to the cap plate and the can and inhibit corrosion of the can
Implementation Method 2
a second abuse mode in which the fuse disconnects, responsive to excessive current being generated, the terminal block from the cap plate... in a second abuse mode to disconnect, responsive to a current exceeding a predetermined threshold, the terminal block from the cap plate
Implementation Method 3
an insulating member disposed between the terminal block and the cap plate... The insulating member is configured to insulate the cap plate from the terminal block
Data Source
AI summary
A cell that includes a can and an electrode assembly disposed in the can, the electrode assembly including at least one positive electrode and at least one negative electrode. The cell also includes a cap assembly at a positive terminal of the cell, the cap assembly includes a terminal block, a cap plate, an insulating member disposed between the terminal block and the cap plate, and a fuse disposed in a region of the insulating member. The insulating member is configured to insulate the cap plate from the terminal block, and the fuse is operable in two modes: a first cathodic mode in which the fuse electrically connects the terminal block to the cap plate and a second abuse mode in which the fuse disconnects, responsive to excessive current being generated, the terminal block from the cap plate.