Connection Sheet Layout for Overcurrent Capacity and Low Heat Rise
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Solution Overview
Problem
The existing connection sheet design requires numerous verifications to ensure adequate overcurrent capacity, leading to high verification costs and inefficiencies in the geometric dimension of the soft connection region, which complicates the design process.
Innovation Solution
A design method for a connection sheet that divides the welding region into a first effective region and a second effective region, where the first effective region is split into multiple regions on the same side of the second effective region, with the gauge size determined by a ratio (S=a*S1) within a specific range (0.095-0.96), ensuring the overcurrent capacity and temperature rise requirements are met during charging-and-discharging cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the geometric dimension of the soft connection region is verified multiple times to ensure adequate overcurrent capacity, then the reliability of the connection sheet is improved, but the verification cost and design complexity increase significantly
Solution Approach 1:
The patent applies parameter changes by establishing a specific ratio relationship between the welding region area S and the first effective region area S1, where S=a*S1 and a is in the range of 0.095-0.96. This parameter-based design method replaces multiple geometric dimension verifications with a single ratio calculation, reducing design complexity while ensuring adequate overcurrent capacity through the controlled area ratio
Solution Approach 2:
The connection sheet is segmented into distinct functional regions: a welding region, a first effective region with regular shape, and a second effective region connectable to the terminal post. This segmentation allows each region to be optimized independently with clear functional boundaries, simplifying the verification process by focusing on the critical welding region-to-effective region area ratio rather than complex overall geometry
2Reliability
If the area of the welding region is increased to improve overcurrent capacity, then the reliability is improved, but the temperature rise during charging-and-discharging cycles increases
Solution Approach 1:
The patent resolves this contradiction by controlling the area ratio parameter a=S/S1 within the specific range of 0.095-0.96. This parameter optimization ensures that the welding region area S is appropriately sized relative to the first effective region area S1, providing sufficient overcurrent capacity while limiting temperature rise to below 10°C during charging-and-discharging cycles
Solution Approach 2:
The connection sheet design applies local quality by creating distinct regions with different functions: the welding region optimized for electrical connection, the first effective region with regular shape for current distribution, and the second effective region for terminal post connection. This regional differentiation allows localized optimization of current density and heat distribution, preventing excessive temperature rise while maintaining overcurrent capacity
Data Source
AI summary
The disclosure provides a design method for a connection sheet, a connection sheet, and an energy storage device. The design method for the connection sheet includes: an area S of a welding region, connectable to a tab, of the connection sheet is obtained; the connection sheet is divided into a first effective region and a second effective region, where the first effective region is a region, having a regular shape, of the connection sheet, the second effective region is a region, connectable to a terminal post, of the connection sheet, the first effective region is implemented as N first effective regions, N≥1, and multiple first effective regions are connected on the same side of the second effective region; a gauge size of the first effective region is determined according to S=a*S1, a being in a range of 0.095˜0.96, and S1 being an area of the first effective region.