Battery Connector Thermal Protection Using Temperature Difference
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Solution Overview
Problem
Existing connector systems for electric vehicles are prone to thermal overload, leading to potential connection failures and increased costs due to the need for oversized components to account for environmental tolerances, which can result in inefficient designs and higher manufacturing costs.
Innovation Solution
A connector system that includes temperature sensors for the negative and positive connection elements, a control unit to monitor temperature differences, and generate alert signals when thresholds are exceeded, allowing for precise protection against thermal overload without the need for additional current measurement equipment, thus enabling a more efficient and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors and control unit are added to monitor connection elements, then protection against thermal overload is improved, but device complexity increases
Solution Approach 1:
The patent combines the temperature monitoring function with the existing connector system by integrating temperature sensors into the connection elements and using a control unit that receives temperature signals. This merging approach allows thermal protection to be implemented within the existing connector architecture rather than as a completely separate system, thereby improving reliability while limiting the increase in device complexity.
2Manufacturing precision
If temperature monitoring is implemented, then manufacturing precision requirements are reduced, but device complexity increases
Solution Approach 1:
The patent replaces mechanical/physical design margins (oversized components to account for environmental tolerances) with a thermal monitoring system. Instead of designing connectors with excessive size and robustness to handle all possible thermal conditions, the system uses temperature sensors and control logic to actively monitor and respond to actual thermal conditions, thereby reducing manufacturing precision requirements while managing the added complexity through electronic control.
3Reliability
If connection elements are oversized to account for environmental tolerances, then reliability is improved, but weight and volume increase
Solution Approach 1:
The patent introduces dynamic thermal monitoring and control to replace static oversized design. Instead of designing connection elements to be permanently oversized to handle worst-case environmental conditions, the system dynamically adjusts protection based on real-time temperature measurements. This allows connection elements to be optimized for normal operating conditions while the control unit provides adaptive protection, thereby reducing weight while maintaining reliability.
4Reliability
If connection elements are oversized to account for environmental tolerances, then reliability is improved, but manufacturing costs increase
Solution Approach 1:
The patent changes the approach from static parameter design (oversized components) to dynamic parameter control (temperature monitoring and response). By using temperature sensors to detect actual thermal conditions and the control unit to respond accordingly, the system allows connection elements to be manufactured at optimal sizes for normal operation rather than being oversized for worst-case scenarios. This parameter change from static to dynamic control reduces material costs while maintaining reliability through active monitoring.
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
This solution provides accurate protection against thermal overload, reducing the risk of connection failures and allowing for a smaller, less expensive connector design by directly monitoring temperature, thereby enhancing the efficiency and reducing the manufacturing costs of the connector system.
Implementation Method 1
a first temperature sensor thermally connected to the negative connection element; a second temperature sensor thermally connected to the positive connection element
Data Source
AI summary
In a connector system for a battery system, the connector system includes: a connector configured to electrically connect to a counterpart of the connector, wherein the connector comprises a negative connection element and a positive connection element; a first temperature sensor thermally connected to the negative connection element; a second temperature sensor thermally connected to the positive connection element; and a control unit configured to receive a first temperature signal from the first temperature sensor and to receive a second temperature signal from the second temperature sensor; wherein the control unit configured to generate a first value based on the first temperature signal and a second value based on the second temperature signal; and wherein the control unit is further configured to generate an alert signal in response to an absolute value of a difference between the first value and the second value exceeding a predefined threshold.