Battery Conductor Connection Structure with Integrated Fuse

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Solution Overview

Problem

Conventional conductive modules for battery systems in electric vehicles have a large number of components, including relays, which increases size and complexity, limiting downsizing opportunities.

Innovation Solution

A connection structure that includes a direct or indirect connection between a bus bar and battery cell electrodes, a fuse element between the bus bar and a linear conductor, and a resin mold member with insulation properties, reducing the need for additional relay terminals and simplifying assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fuse is interposed between the connection conductor and the linear conductor, then overcurrent protection is achieved, but the number of relay components increases

Engineering Contradiction:

Improveovercurrent protectionVSAvoidnumber of relay components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the fuse element with the resin mold member into an integrated assembly. The resin mold member houses and secures the fuse element, creating a unified component that eliminates the need for separate relay terminals and reduces the number of discrete parts while maintaining overcurrent protection functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The resin mold member serves multiple functions: it provides structural support, electrical insulation, mechanical securing of the fuse element, and integration with the connection conductor. This multi-functional design reduces the overall component count while achieving the required overcurrent protection

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple relay components are used to connect the connection conductor and linear conductor, then overcurrent protection is achieved, but the size of the conductive module increases

Engineering Contradiction:

Improveovercurrent protectionVSAvoidsize of conductive module

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The fuse element and resin mold member are merged into a single integrated assembly that occupies less space than separate relay components would require. This consolidation directly reduces the volume of the conductive module while maintaining the overcurrent protection function

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fuse element is nested within the resin mold member, with the resin mold member providing a housing that contains and protects the fuse element. This nested arrangement minimizes the overall volume required for the overcurrent protection assembly

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If multiple relay components are used in the connection structure, then overcurrent protection is achieved, but the weight of the conductive module increases

Engineering Contradiction:

Improveovercurrent protectionVSAvoidweight of conductive module

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The integration of the fuse element with the resin mold member eliminates the need for additional relay terminals and mounting hardware, directly reducing the total weight of the conductive module while preserving the overcurrent protection capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The resin mold member provides a lightweight, cost-effective housing for the fuse element that replaces heavier metal relay components. This substitution reduces both weight and cost while maintaining the required protection function

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 number of components, decreases the size and weight of the conductive module, lowers component costs, and enhances overcurrent protection while improving assembly efficiency and voltage detection accuracy.

Implementation Method 1

a fuse element that is directly or indirectly connected between the connection conductor and the linear conductor, and that melts when overcurrent flows between the connection conductor and the linear conductor

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

a resin mold member that has an insulation property and that includes the fuse element and a part of the connection conductor

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS11043721B2Connection structure of conductor and conductive module

Publication Date: 2021.06.22 YAZAKI CORP

AI summary

A conductor includes a connection conductor that is directly connected to at least one of a plurality of electrode terminals of an electrode terminal group of a plurality of battery cells arranged in a same direction; a linear conductor that is connected to a battery monitoring unit configured to monitor a battery state of the battery cells; a fuse element that is indirectly connected between the connection conductor and the linear conductor, and that melts when overcurrent flows between the connection conductor and the linear conductor; and a resin mold member that has an insulation property and that includes the fuse element, a part of the connection conductor, and a part of a relay terminal.