Dual-Contact Breaker Layout for Low-Resistance Battery Packs
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Solution Overview
Problem
The existing breaker design with a pair of contacts connected in series faces challenges in reducing resistance between terminals, making it difficult to achieve efficient electrical conductivity.
Innovation Solution
The breaker design incorporates a movable piece with two movable contacts and two fixed contacts, forming parallel circuits between terminal pieces, utilizing a thermally-actuated element to separate contacts and reduce resistance, with specific structural features like bent portions and protrusions to enhance contact pressure and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a pair of contacts are connected in series, then the breaker structure is simple, but the resistance between terminals increases
Solution Approach 1:
The movable contact is divided into two separate movable contacts (first movable contact and second movable contact) positioned at different end portions of the movable piece. This segmentation allows the formation of two parallel contact paths, reducing overall resistance while maintaining structural simplicity.
Solution Approach 2:
The patent transitions from a single contact path (one-dimensional) to a parallel dual contact path configuration (two-dimensional arrangement). By positioning contacts at both end portions of the movable piece and connecting them in parallel between terminal pieces, the invention reduces resistance without significantly increasing structural complexity.
2Volume of moving object
If the movable piece is made compact, then the breaker size is reduced, but the contact pressure between movable and fixed contacts decreases
Solution Approach 1:
The movable piece incorporates asymmetric bent portions (first bent portion and second bent portion) at different locations. These bent portions create localized stress concentration points that enhance contact pressure at specific contact regions, allowing compact dimensions while maintaining adequate contact force through strategic geometric design.
Solution Approach 2:
The bent portions of the movable piece introduce curved geometries that concentrate mechanical stress at the contact points. This curvature design amplifies contact pressure in the compact structure by creating elastic deformation zones that press the movable contacts against the fixed contacts more effectively.
3Volume of moving object
If the breaker is miniaturized, then the device size is reduced, but the stability under impact and thermal conditions deteriorates
Solution Approach 1:
The movable piece incorporates localized protrusions at specific positions that act as reinforcement features. These protrusions are strategically positioned to enhance structural rigidity and resistance to impact forces in critical areas, allowing the overall device to be miniaturized while maintaining stability under thermal and mechanical stress through localized strengthening.
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 configuration reduces the resistance between terminal pieces by creating parallel circuits and ensuring reliable conductivity, even under varying conditions such as overcharging or impact, while maintaining a compact and miniaturized structure.
Implementation Method 1
a thermally-actuated element deforming with a change in temperature and moving the movable piece so that the movable contact is separated from the fixed contact
Data Source
AI summary
A breaker is provided with a first terminal piece on which a fixed contact is formed, a movable piece with a movable contact for pressing the movable contact against the fixed contact so as to contact therewith, a thermally-actuated element deforming with a change in temperature and moving the movable piece so that the movable contact is separated from the fixed contact, and a second terminal piece electrically connected to the movable piece. The movable contact includes a first movable contact and a second movable contact arranged at a first end portion and a second end portion, respectively, of the movable piece in its longitudinal direction. The fixed contact includes a first fixed contact arranged at a position with which the first movable contact can contact, and a second fixed contact arranged at a position with which the second movable contact can contact.