Battery Connection Module With Replaceable Fuse Bridge PCB
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Solution Overview
Problem
Existing battery connection systems face issues with high-value circuit boards being scrapped due to welding problems during manufacturing and overcurrent events, where the circuit with fusible wires can only be repaired once, leading to the entire battery pack being scrapped if the circuit cannot be repaired.
Innovation Solution
A battery connection module comprising a carrying tray, busbars, a main circuit board, and a bridging circuit board, where the bridging circuit board acts as a bridge connecting first and second wirings with fuse segments, allowing for separate functions and enabling simple replacement of the bridging circuit board when a fuse is melted, without needing to replace the main circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If connectors or electronic components are provided on the same circuit board and welded with busbars, then the circuit board can perform multiple functions, but welding problems during manufacturing or overcurrent events result in the entire high-value circuit board being scrapped
Solution Approach 1:
The circuit board is divided into two separate functional modules: a main circuit board containing connectors and electronic components, and a separate fusible circuit board containing the fusible wire and wiring. This segmentation allows the fusible circuit board to be replaced independently when damaged, preventing loss of the entire assembly and enabling cost-effective repairs.
2Reliability
If a fusible wire is connected in parallel with an operating connector on the same circuit board, then overcurrent protection is achieved, but the circuit can only be repaired once before the entire board must be scrapped
Solution Approach 1:
The fusible wire is placed on a separate fusible circuit board that can be independently replaced. After the fusible wire melts during overcurrent protection, only this separate board needs to be replaced, allowing multiple repair cycles and extending the service life of the expensive main circuit board and electronic components.
Solution Approach 2:
The fusible circuit board is designed as a disposable, low-cost component that sacrificially fails during overcurrent events. This allows the expensive main circuit board and electronic components to be preserved and reused, reducing overall system cost and improving repairability.
3Reliability
If the entire circuit board with electronic components is replaced after a fuse interruption, then circuit reliability is restored, but the cost increases and battery pack life is reduced
Solution Approach 1:
The circuit board system is segmented into replaceable modules, allowing only the damaged fusible circuit board to be replaced rather than the entire assembly. This reduces manufacturing costs and extends the operational life of the battery pack by enabling economical repairs.
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 simplifies repairs and reduces costs by allowing the bridging circuit board to be replaced easily when a fuse is interrupted, preventing the need to replace the entire main circuit board, thus extending the life of the battery connection module.
Implementation Method 1
the fusible wire connected with the operating connector in parallel may make the fusible wire connected with the operating connector in parallel melted and interrupted when a circuit is in overcurrent
Implementation Method 2
the first pad and the second pad of the operating connector are welded with a solder so as to make the first pad and the second pad short-circuited
Data Source
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AI summary
A battery connection module is used to connect a plurality of batteries, the battery connection module includes a carrying tray, a plurality of busbars, a main circuit board and a bridging circuit board, the plurality of busbars are assembled on the carrying tray, the plurality of busbars are used to connect the plurality of batteries; the main circuit board includes a plurality of first wirings and a plurality of second wirings, connect points of one ends of the plurality of first wirings are converged to a first connect point connection region, the other ends of at least some of the plurality of first wirings connect the plurality of busbars, one ends of the plurality of second wirings connect operating components mounted on the main circuit board and connect points of other ends of the plurality of second wirings are converged in a second connect point connection region; the bridging circuit board includes a plurality of bridging wirings which are used to respectively bridge the plurality of first wirings of the first connect point connection region and the plurality of second wirings of the second connect point connection region, each bridging wiring includes a fuse segment thereon.