Charging Port Clamping Device for Thermal Runaway Prevention
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Solution Overview
Problem
Battery-operated products face risks of thermal runaway events due to increased power output in charging ports, leading to potential fires and reduced battery performance, as elevated temperatures can cause detachment of the charging port from the circuit board and heat transfer to other components.
Innovation Solution
A case device with a clamping device attached to the circuit board to securely attach the charging port, preventing detachment during thermal runaway events, combined with a thermally insulating material to reduce heat transfer to the rechargeable battery and a polymer main housing that melts at a temperature below the thermal runaway threshold of lithium-ion batteries to dissipate heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the power output through charging cables and charging ports is increased to achieve faster charging times, then the charging speed is improved, but the risk of thermal runaway events increases
Solution Approach 1:
The patent introduces a clamping device that segments the connection between the charging port and circuit board into two independent attachment mechanisms: soldering and mechanical clamping. This segmentation ensures that if one attachment method fails due to thermal runaway, the other maintains the connection, allowing the system to withstand higher power outputs without increased risk.
Solution Approach 2:
The clamping device acts as a pre-prepared safety mechanism that compensates for potential soldering failures before they occur. By providing an additional attachment method in advance, the system is cushioned against the harmful effects of thermal runaway events that may occur during high-power charging operations.
2Object-affected harmful factors
If the charging port is securely attached to the circuit board to prevent detachment during thermal runaway, then the fire hazard risk is reduced, but the device complexity increases
Solution Approach 1:
The patent merges two attachment methods (soldering and mechanical clamping) into a single integrated connection system. The clamping device is designed to work in conjunction with existing soldered connections, combining the strengths of both methods to prevent detachment while adding minimal complexity to the overall assembly process.
Solution Approach 2:
The clamping device serves as an intermediary mechanical fastener between the charging port and circuit board. This intermediary component provides the additional security needed to prevent detachment during thermal runaway without requiring complete redesign of the existing soldered connection system.
3Reliability
If thermal insulation material is added between the charging port and battery to prevent heat transfer, then the battery safety is improved, but the device complexity increases
Solution Approach 1:
The patent extracts the thermal insulation function from the main housing structure and implements it through a specific insulating element positioned between the charging port and battery. This extraction allows the insulation function to be added independently without redesigning the overall device structure, maintaining simplicity while improving battery safety.
4Object-affected harmful factors
If the main housing is designed to melt at a temperature below the thermal runaway threshold to dissipate heat, then the fire safety is improved, but the structural strength is reduced
Solution Approach 1:
The patent applies local quality by using different materials with different thermal properties in different parts of the device. The main housing uses a higher melting point material for structural strength, while specific internal components or linings use lower melting point materials that can dissipate heat by melting before the main structure fails, maintaining overall fire safety without compromising structural integrity.
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 the risk of fire hazards by maintaining the charging port attachment and preventing thermal runaway events in the battery, while ensuring the main housing can safely dissipate heat and prevent fires.
Implementation Method 1
a clamping device attached to the first circuit board and being configured for clamping the charging port onto the first circuit board
Implementation Method 2
combined with a thermally insulating material to reduce heat transfer to the rechargeable battery
Implementation Method 3
a polymer main housing that melts at a temperature below the thermal runaway threshold of lithium-ion batteries to dissipate heat
Data Source
AI summary
The present disclosure relates to a case device comprising a rechargeable battery and a charging port electrically connected to the rechargeable battery and connected to a first circuit board. The case device further comprises a clamping device attached to the first circuit board and being configured for clamping the charging port onto the first circuit board.