Fusible Electrical Connector for Battery Cell Thermal Runaway Protection
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Solution Overview
Problem
Lithium-ion batteries in portable electrical energy storage devices face risks of internal or external short-circuiting, leading to potential combustion and instability due to their electrolyte solutions, especially when multiple cells are connected, as thermal energy can cause neighboring cells to fail and ignite, and existing thermal fusing methods struggle with reliable contact on small terminals.
Innovation Solution
The development of electrical connectors with integral conductive tabs and supports that include conductive bands with varying cross-sectional areas, allowing for thermal fusion and electrical isolation when current thresholds are exceeded, preventing further damage to failing cells and stabilizing non-failing cells by melting or 'frying' when excessive current is detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple lithium-ion battery cells are connected to increase energy storage capacity, then the energy density and power output are improved, but the risk of thermal runaway and combustion increases due to potential short-circuiting and electrolyte instability
Solution Approach 1:
The patent introduces an electrical connector as an intermediary component between battery cells that includes a fusible element. This mediator normally conducts electricity but melts and breaks the circuit when excessive current causes thermal runaway, thereby protecting the battery system while allowing high capacity operation.
Solution Approach 2:
The patent converts the harmful thermal energy from short-circuiting into a protective mechanism. The fusible element is designed to melt at specific temperature thresholds, transforming the dangerous heat generation into a controlled circuit-breaking action that isolates failing cells and prevents system-wide combustion.
2Reliability
If thermal fusing methods are used to attach connectors to battery terminals, then electrical isolation during failure is achieved, but reliable contact becomes difficult due to the small size of battery terminals
Solution Approach 1:
The electrical connector is segmented into distinct functional zones: a larger support structure for mechanical stability and manufacturing access, and a smaller fusible element for electrical isolation. This segmentation allows the connector to be manufactured and attached reliably to small terminals while maintaining the thermal fusing capability.
Solution Approach 2:
The connector exhibits local quality with different portions having different properties. The support structure provides mechanical strength and ease of attachment, while the fusible element provides thermal response and electrical isolation. This localized differentiation enables both reliable manufacturing contact and effective failure protection.
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 electrical connectors effectively isolate failing cells from others, preventing further damage and reducing the risk of thermal instability and combustion, while ensuring reliable contact and attachment to the terminals of portable energy storage cells, enhancing safety and stability in battery banks.
Implementation Method 1
configured to cut off electric connection with the storage elements by fusing at the time when a current of a predetermined value or more flows therein
Implementation Method 2
melting or 'frying' when excessive current is detected
Data Source
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AI summary
Electrical connectors for electrically connecting individual portable electrical energy storage cells making up a plurality of portable electrical energy storage cells that are part of a portable electrical energy storage device for powering portable devices such as vehicles or consumer electronics include bands of reduced cross-sectional area. The electrical connectors include conductive bands that promote reliable attachment between the electrical connector and portable electrical energy storage cells and provide the ability to electrically isolate failing or damaged cells.