Battery Busbar Fuse Structure for Stable High-Current Packs
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Solution Overview
Problem
Existing battery packs for devices like processing devices, chargers, and transport devices lack mechanical stability and efficient electrical connections, particularly in high-current applications, which can lead to premature failure and safety concerns.
Innovation Solution
A battery pack design featuring a busbar unit with an electrically conductive core body and an insulating stabilization body, including a fuse section with a reduced cross-section for mechanical and electrical connection, and a bridge section for enhanced stability, which automatically interrupts the electrical path in case of overload, ensuring reliable and safe energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar unit with reduced cross-section fuse section is used, then electrical connection reliability is improved through automatic overload interruption, but mechanical strength is reduced due to the tapered fuse section
Solution Approach 1:
The busbar unit is segmented into distinct functional zones: embedding sections with full cross-section for mechanical strength, a tapered fuse section for overload protection, and bridge sections for structural support. This segmentation allows each zone to optimize its properties independently.
Solution Approach 2:
The busbar unit combines electrically conductive material (copper or aluminum) with electrically insulating material to create a composite structure. The insulating material compensates for the reduced mechanical strength in the fuse section while maintaining electrical conductivity where needed.
2Reliability
If embedding sections are completely surrounded by insulating material, then electrical insulation is improved, but assembly complexity increases due to additional manufacturing steps
Solution Approach 1:
The insulating material is merged with the busbar unit into a single integrated component through co-molding or overmolding processes. This eliminates the need for separate assembly steps to attach insulating covers, reducing manufacturing complexity while maintaining complete electrical insulation.
Solution Approach 2:
The combination of conductive and insulating materials is achieved through composite manufacturing techniques where both materials are processed simultaneously or sequentially in one operation, creating an integrated structure that combines electrical conductivity and insulation without requiring multiple assembly steps.
3Stability of the object's composition
If bridge sections are added to support embedding sections, then mechanical stability is improved, but device complexity increases due to additional structural components
Solution Approach 1:
The bridge sections are merged with the insulating material and the busbar unit into a single integrated component. The insulating material itself forms the bridge sections that connect and support the embedding sections, eliminating the need for separate structural support components.
Solution Approach 2:
The insulating material serves multiple functions simultaneously: it provides electrical insulation, structural support through bridge sections, and mechanical connection between embedding sections. This multi-functionality reduces the total number of components needed while maintaining mechanical stability.
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 design provides a mechanically stable and compact battery pack with enhanced safety features, allowing for reliable operation in high-current applications while simplifying assembly and reducing the risk of premature failure.
Implementation Method 1
The fuse section (9) with a reduced cross-section relative to the two embedding sections (7, 8)... The fuse section can form a predetermined breaking point in the core body for the automatic interruption of an electrical conduction path formed by the core body in the event of an overload
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a battery pack (1) for a battery device (50), wherein the battery pack (1) comprises: a battery cell pack (2), a connection device (3), and at least one electrical busbar unit (4) that electrically connects the battery cell pack (2) to the connection device (3), wherein the busbar unit (4) comprises an electrically conductive core body (5) and an electrically insulating stabilizing body (6) made of or with electrically insulating material, wherein the core body (5) comprises a first embedding section (7) facing the connection device (3) and a second embedding section (8) facing away from the first embedding section (7), wherein the core body (5) comprises a fuse section (9) with a reduced cross-section relative to the two embedding sections (7, 8), through which the two embedding sections (7, 8) are electrically and mechanically connected to each other.wherein the two embedding sections (7, 8) are each embedded in the electrically insulating material of the stabilizing body (6), and wherein the stabilizing body (6) has at least one bridge section (10) which extends at a distance (A) from the fuse section (9) between the two embedding sections (7, 8) in order to mechanically support the two embedded embedding sections (7, 8) against each other in addition to their connection by the fuse section (9).