Battery Busbar Interconnector With Built-In Cell Fuse Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power units face challenges with faulty cells causing short circuits and thermal runaway, leading to reduced battery life and increased complexity and cost due to the need for external electrical fuses and complex design changes.
Innovation Solution
The design incorporates an interconnector with an inherent neck fusing element that isolates faulty cells by acting as a fusing element when excessive current is detected, eliminating the need for external fuses and simplifying the design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external electrical fuses are connected with the plurality of cells to prevent damage, then the reliability of the battery is improved, but the device complexity and packaging requirements increase
Solution Approach 1:
The patent merges the interconnector and fuse into a single integrated component. The interconnector serves dual functions: electrical connection between cells and fault isolation through its breakable design. This eliminates the need for separate external fuses and reduces design complexity while maintaining battery reliability.
Solution Approach 2:
The interconnector is designed to perform multiple functions: it acts as both an electrical conductor connecting cells in series/parallel configurations and a protective fuse element. This multi-functionality reduces the number of components needed and simplifies the overall battery design.
2Reliability
If external electrical fuses are used to isolate faulty cells, then the reliability is improved, but the space inside the battery increases
Solution Approach 1:
By combining the fuse function with the interconnector, the patent eliminates the need for separate fuse components that would occupy additional space. The breakable interconnector integrates fault isolation capability directly into the existing electrical connection structure, reducing overall battery volume.
3Reliability
If precautionary devices are added to isolate faulty cells connected in parallel, then the reliability is improved, but the overall cost of the battery pack increases
Solution Approach 1:
The interconnector is designed to serve as both an electrical conductor and a protective fuse element. This multi-functional design eliminates the need for separate precautionary devices, reducing component count, design complexity, and overall cost while maintaining the ability to isolate faulty cells.
Solution Approach 2:
The breakable interconnector provides self-service protection by automatically breaking when excessive current flows through it, isolating faulty cells without requiring external control systems or additional protection devices. This passive safety mechanism reduces complexity and cost.
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 effectively prevents short circuits and thermal runaway, reduces the risk of damage, and extends the life of the power unit while simplifying the design and reducing costs by integrating the fusing function within the interconnector.
Implementation Method 1
The neck fusing region acts as a fusing element when a pre-defined passes through said neck fusing region
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A power unit (100) comprising a plurality of cells (102) and each of the plurality of cells (102) are connected using one or more busbars (200). The each of the one or more busbars (200) comprises of a plurality of interconnectors (204, 400), and the each of the plurality of interconnectors (204, 400) comprising a neck fusing region (208) and a second region (210). The neck fusing region (208) being disposed downwardly to connect with the second region (210). The neck fusing region (208) being configured to act as a fusing element when a pre-defined current passes through said neck fusing region (208).