Battery Module Fuse Base Preventing Lead Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In battery modules, the melted fuse can come into contact with leads, causing potential short circuits and operational issues.
Innovation Solution
A battery module design where a conductor functions as a fuse above the lead, with a base positioned between the lead and the fuse to prevent contact, and the fuse is integrated into the conductor structure, allowing it to melt into a designated space without touching the leads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse is disposed above the lead to protect the battery cell, then the fuse can effectively suppress overcurrent, but the melted fuse may come into contact with the lead causing short circuits
Solution Approach 1:
The patent introduces a base as an intermediary component positioned between the fuse and the lead. This base provides a receiving space that captures the melted fuse material, preventing it from contacting the lead. The base acts as a mediator that allows the fuse to perform its protective function while containing the harmful effects of fuse melting.
Solution Approach 2:
The patent converts the harmful effect of melted fuse material into a beneficial containment process. By designing the base with a specific receiving space, the melted fuse is directed into this space, transforming the potentially harmful molten material into a contained element that actually helps seal or secure the connection area.
2Object-affected harmful factors
If a separate base structure is added to prevent fuse contact with leads, then short circuit risk is reduced, but device complexity increases
Solution Approach 1:
The patent merges the base structure with the existing conductor assembly. The base is integrated into the overall conductor design, combining the support function and the fuse containment function into a single unified structure. This integration reduces the number of separate components and simplifies the overall device complexity.
Solution Approach 2:
The base structure serves multiple functions: it supports the conductor, provides a receiving space for melted fuse material, and acts as an insulating barrier between the fuse and lead. This multi-functionality reduces the need for additional separate components, thereby reducing device complexity while maintaining safety.
3Ease of manufacture
If the fuse is integrated into the conductor structure, then manufacturing is simplified, but the fuse may still contact the lead when melted
Solution Approach 1:
The patent applies local quality by creating a specific region (receiving space) within the base structure that is dedicated to containing melted fuse material. This localized design feature ensures that while the fuse is integrated into the conductor, the melted portion is directed into a specific safe zone, preventing contact with the lead without requiring complete structural separation.
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
Prevents the melted fuse from contacting the leads, enhancing safety and reducing the risk of short circuits, while also reducing the module's size and improving connection reliability.
Implementation Method 1
The fuse includes two separated metal plates and solder to connect the two metal plates to each other. A space onto which the solder melted by an overcurrent falls is provided below the solder.
Implementation Method 2
when the fuse is fused, the fused fuse may come into contact with the lead
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery module (50) includes a battery cell (100), a positive electrode lead (112) or negative electrode lead (114) provided in the battery cell (100), a first conductor (400A) electrically connected to the battery cell (100), at least a portion of the first conductor (400A) being functioning as a fuse above the positive electrode lead (112) or the negative electrode lead (114), and a first base (302A), at least a portion of the first base (302A) being located between the positive electrode lead (112) or negative electrode lead (114), and the fuse.