Multi-Metal Battery Connection Member for Thermal Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs face challenges in safely interrupting electric current during abnormal operations like overcharge, overdischarge, or overcurrent, which increases manufacturing costs and complexity, and requires additional safety components.
Innovation Solution
A battery pack design using a connection member made of different metals with varying melting points, where the metal with a lower melting point melts and disconnects when the temperature rises, interrupting current flow without the need for additional safety devices or space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional safety components (sensors, wires, BMS) are added to detect and interrupt current during abnormal operations, then safety is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The connection member automatically detects abnormal temperature conditions and interrupts current flow through its own structural response (melting of low-melting-point metal), eliminating the need for external sensors, control wires, and BMS systems
Solution Approach 2:
The harmful effect of high temperature during abnormal operations is converted into a beneficial protective mechanism, where the temperature itself triggers the melting of the low-melting-point metal in the connection member, automatically interrupting current flow
2Reliability
If additional safety components (sensors, wires, BMS) are added to detect and interrupt current during abnormal operations, then safety is improved, but manufacturing cost increases
Solution Approach 1:
The connection member automatically detects abnormal temperature conditions and interrupts current flow through its own structural response (melting of low-melting-point metal), eliminating the need for external sensors, control wires, and BMS systems
Solution Approach 2:
The connection member uses a low-melting-point metal that is intentionally designed to fail (melt) under abnormal temperature conditions, providing a low-cost sacrificial safety mechanism that replaces expensive electronic safety systems
3Reliability
If multiple members (bus bars, power connection cables) are used for mechanical fastening and electrical connection between battery modules, then connection reliability is improved, but assembly process complexity increases
Solution Approach 1:
The connection member integrates both mechanical fastening function and electrical connection function into a single component, eliminating the need for separate bus bars and power connection cables
Solution Approach 2:
The connection member serves multiple functions simultaneously: it provides mechanical support, electrical conduction, and automatic safety protection through its multi-metal structure with different melting points
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 design enhances safety by automatically disconnecting current flow during abnormal conditions, reduces manufacturing costs, and maintains a compact structure with improved stability and assembly efficiency.
Implementation Method 1
different kinds of metals having different melting points are coupled to each other
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Disclosed herein is a battery pack including two or more battery modules connected to each other, external input and output terminals being formed at one side of each of the battery modules, each of the battery modules including a plurality of unit cells electrically connected to each other while being stacked, wherein the two or more battery modules are connected in series or in parallel to each other via a connection member such that one of the battery modules is connected to an adjacent one of the battery modules, and the connection member is configured to have a structure in which different kinds of metals having different melting points are coupled to each other.