Battery Module Fuse Integration to Eliminate Pack Dead Space
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Solution Overview
Problem
The existing battery modules generate dead space due to the external placement of fuse units, leading to spatial losses and restrictions when mounted in battery packs or vehicles.
Innovation Solution
A battery module design that integrates a fuse unit between busbars within the module case, minimizing external space occupation by using a busbar frame assembly and a fuse unit connected to the busbars, which disconnects upon overcurrent, preventing accidents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the fuse unit is provided outside the battery module, then the fuse unit can be easily mounted and maintained, but dead space is generated causing spatial loss and spatial restriction
Solution Approach 1:
The fuse unit is integrated into the battery module structure by positioning it between the battery cells and electrically connecting it to the busbars. This merging of the fuse unit with the existing battery module components eliminates the need for separate external mounting space, thereby reducing dead space while maintaining the protective function of the fuse unit
Solution Approach 2:
The fuse unit is nested within the battery module assembly by placing it in the space between battery cells and connecting it to the busbar system. This nesting approach allows the fuse unit to occupy space that would otherwise be unused or require separate external accommodation, reducing overall spatial requirements
2Ease of repair
If the fuse unit is provided outside the battery module, then the fuse unit can be independently replaced, but spatial restriction occurs when mounted in battery pack or vehicle
Solution Approach 1:
The fuse unit is designed as a separable component that can be independently removed from the battery module. The electrical connection between the fuse unit and busbars is made through connection members that allow for easy disconnection and replacement, maintaining ease of repair while enabling compact integration within the battery module structure
3Volume of moving object
If the fuse unit is integrated between busbars within the module case, then dead space is minimized and compactness is enhanced, but the complexity of electrical connection increases
Solution Approach 1:
The busbars serve multiple functions: they provide electrical connection between battery cells in series/parallel configurations and also serve as connection points for the fuse unit. This multi-functionality reduces the need for additional dedicated connection components, simplifying the overall electrical connection structure while integrating the fuse unit within the battery module
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 minimizes dead space and prevents spatial restrictions, enhancing the compactness and efficiency of battery modules, packs, and vehicles by integrating the fuse unit internally within the module case.
Implementation Method 1
a fuse unit which is disconnected to cut off a current of the battery module when the current exceeds an allowable current, in order to prevent an accident such as explosion of battery cells due to overvoltage or overcurrent
Implementation Method 2
a busbar frame assembly slidably inserted into the module case to support the plurality of battery cells and including a plurality of busbars electrically connected to electrode leads of the plurality of battery cells
Data Source
AI summary
A battery module according to an embodiment of the present disclosure includes a plurality of battery cells, a module case accommodating the plurality of battery cells therein, a busbar frame assembly slidably inserted into the module case to support the plurality of battery cells, the busbar frame assembly including a plurality of busbars electrically connected to electrode leads of the plurality of battery cells, and a fuse unit connected to at least one pair of busbars of the plurality of busbars, the fuse unit being provided between the at least one pair of busbars.