Battery Safety Interconnect With Pyro Fuse Module Disconnect
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Solution Overview
Problem
Existing high-voltage battery systems for electric vehicles require extensive safety training and special equipment for servicing due to the use of bolted joints, which are costly and time-consuming, and pose risks during disassembly.
Innovation Solution
A safety interconnect system with a housing made of electrically insulating material, containing a busbar with terminals and an active current disconnect, such as a pyrotechnic fuse, that allows for safe disconnection of high-voltage modules without exposing technicians to lethal voltages, enabling easy servicing without specialized tools or training.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolted joints are used to electrically couple battery modules, then reliable electrical connection is achieved, but manufacturing cost and assembly time increase significantly
Solution Approach 1:
The patent replaces the mechanical bolted joint system with a welding-based electrical coupling system. The welding process creates direct metal-to-metal bonds between battery module terminals and interconnectors, eliminating the need for bolts, nuts, and complex mechanical fastening systems. This substitution maintains electrical reliability while dramatically simplifying assembly operations and reducing manufacturing costs.
Solution Approach 2:
The patent merges the electrical connection function with the structural support function into a single welded joint. The weld simultaneously provides both the electrical conductive path and the mechanical strength to hold modules together, eliminating the need for separate electrical connectors and mechanical fasteners that would be required with bolted systems.
2Ease of repair
If bolted joints are used for module connection, then disassembly is possible, but service requires extensive high-voltage safety training and special equipment
Solution Approach 1:
The patent segments the battery pack into modular units with standardized welding interfaces, allowing individual modules to be removed and replaced independently. Each module is designed as a self-contained unit with external terminals that can be electrically decoupled through selective welding removal, enabling modular servicing without requiring technicians to handle high-voltage connections directly.
Solution Approach 2:
The patent introduces external terminals as intermediary connection points between battery modules and the rest of the system. These terminals serve as safe access points for electrical connections, allowing current to be routed through isolated pathways that keep high-voltage components away from service areas, thereby reducing safety risks during maintenance operations.
3Ease of operation
If modules are electrically coupled by bolted joints, then assembly is straightforward, but manufacturing costs and assembly time increase
Solution Approach 1:
The patent replaces time-consuming mechanical fastening operations with rapid welding processes. The welding system can join multiple modules simultaneously or in rapid sequence, eliminating the need for technicians to manually position and fasten multiple bolts per connection point. This substitution maintains operational simplicity while reducing assembly time by a factor of several times.
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 safety interconnect system reduces the risk of electrical shock by safely disconnecting high-voltage modules, allowing for easy and cost-effective servicing of electric vehicle battery systems without the need for specialized training or equipment, enhancing safety and reducing operational costs.
Implementation Method 1
The active current disconnect comprises a pyrotechnic fuse
Data Source
AI summary
A safety interconnect for a modular high-voltage battery system comprises: a housing of an electrically insulating material, the housing having a cavity with an opening; and a busbar contained within the cavity, the busbar comprising a first terminal for connecting to a first external terminal of a first module of a modular high-voltage battery system, and a second terminal for connecting to a second external terminal of a second module of the modular high-voltage battery system adjacent the first module.