Battery Module PCB Fuse Access for Overcurrent Protection
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Solution Overview
Problem
Battery modules are prone to explosion or ignition due to overcurrent, posing safety risks and hindering rapid reuse due to complex fuse replacement processes.
Innovation Solution
A battery module with a PCB assembly that includes a fuse to cut off current when overcurrent occurs, featuring a detachable cover for easy replacement and a transparent cover to monitor fuse status, ensuring safety and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuse is integrated into the battery module to prevent overcurrent, then safety is improved, but the complexity of fuse replacement increases
Solution Approach 1:
The fuse is segmented from the main PCB assembly and mounted on a separate fuse holder that can be independently accessed. The fuse holder is positioned through the cover plate, allowing the fuse to be replaced without disassembling the entire battery module or removing the cover plate, thus maintaining safety while simplifying replacement complexity.
Solution Approach 2:
The fuse is extracted from the internal PCB structure and relocated to an accessible position through the cover plate. This extraction allows the fuse to be serviced independently from the main circuit board, enabling rapid replacement without complex disassembly procedures while maintaining the overcurrent protection function.
2Loss of time
If the fuse is made easily replaceable, then maintenance time is reduced, but the protection of the fuse from external impact is worsened
Solution Approach 1:
The fuse holder is nested within the case structure but accessed through the cover plate. The fuse holder can be inserted and removed through the opening in the cover plate while remaining protected by the case structure. This nesting arrangement allows quick access for replacement while maintaining protection from external impacts through the case and cover plate structure.
Solution Approach 2:
The cover plate is designed with a localized opening specifically positioned to provide access to the fuse holder. This localized access point allows maintenance personnel to quickly reach and replace the fuse without compromising the overall protective enclosure. The opening is strategically positioned to balance accessibility with structural integrity and protection from external impacts.
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 solution effectively prevents explosions and ignitions by quickly cutting off overcurrent, allowing for rapid and safe replacement of the fuse, enhancing safety and facilitating easy maintenance.
Implementation Method 1
the fuse is melted due to heat generated while the current exceeding the preset value flows to cut off the electricity
Data Source
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AI summary
A battery module of the present invention includes: a stack provided as one or more battery cells; a case in which the stack is accommodated; and a PCB assembly provided inside the case and configured to electrically connect a first busbar provided at one side of the stack to a second busbar provided at the other side of the stack or cut off electricity so as not to flow when current exceeding a preset value flows, wherein the PCB assembly includes: a first connection cable connected to the first busbar; a second connection cable connected to the second busbar; and a PCB provided with a circuit configured to electrically connect the first connection cable to the second connection cable and a fuse configured to cut off the electricity so as not to flow through the circuit when the current exceeding the preset value flows through the circuit.