Battery Module Fusible Link Parallel Connection Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery packs face issues where a problem in one battery connected in series causes the entire pack to stop operating, and internal short-circuits in parallel batteries lead to excessive heat and potential ignition, wasting unaffected batteries.
Innovation Solution
A battery module design where batteries are connected in parallel using fusible links made of the same material as the connection terminal and base, allowing for safe disconnection of faulty batteries to prevent unsafe operation and prolong the life of the remaining batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal fuse is connected to battery leads by soldering for safety protection, then the battery pack can detect and respond to thermal runaway, but the workability and productivity deteriorate due to the risk of the thermal fuse being blown at connection temperature
Solution Approach 1:
The patent replaces the traditional soldered thermal fuse connection with a mechanical press-fit connection system. The connection plate with through-holes allows thermal fuses to be mechanically inserted and secured without soldering, eliminating the risk of thermal fuse damage during soldering while maintaining safety protection functionality.
Solution Approach 2:
The patent introduces a connection plate as an intermediary component between the battery leads and thermal fuses. This connection plate provides a dedicated mechanical interface that simplifies the connection process and protects the thermal fuses from thermal damage during assembly, improving both manufacturability and reliability.
2Reliability
If a fuse is blown to stop operation when a battery problem occurs, then safety is improved by preventing further damage, but the batteries having no problem go to waste
Solution Approach 1:
The patent divides the battery pack into independent modular units, each with its own connection plate and thermal fuse protection. This segmentation allows individual faulty batteries or modules to be isolated and removed without affecting the operation of other healthy modules, preventing waste of functioning batteries while maintaining safety.
3Quantity of substance
If batteries are connected in parallel to increase capacity, then the energy storage and output capability are improved, but the risk of excessive heat and ignition from internal short-circuits increases
Solution Approach 1:
The patent implements individual thermal fuse protection for each battery or module connected in parallel. By segmenting the protection system to match the parallel configuration, each battery has its own safety mechanism that can independently respond to internal short-circuits, preventing thermal propagation to other batteries while maintaining the high capacity benefits of parallel connection.
Solution Approach 2:
The connection plate serves as an intermediary that facilitates safe parallel connections by providing dedicated pathways for current flow and thermal fuse insertion. This structured intermediate interface enables scalable parallel configurations with maintained safety control over heat and ignition risks.
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 failure operations by safely disconnecting faulty batteries, ensuring the battery module's reliability and longevity while reducing thermal influences and gas ignition risks.
Implementation Method 1
the thickness of the foaming layer is increased by excessive heat generated in the battery so that the contact is opened
Implementation Method 2
an example of a battery pack in which PTC elements and fuses are connected in series
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3~4
AI summary
In a battery module including a plurality of batteries 40 stored in a housing, each of the batteries 40 includes an electrode portion 16 protruding from a battery case 5, a base 30A is arranged on a side of the electrode portions 16 so that the base 30A is in contact with the battery cases 5, and the electrode portions 16 are inserted in through holes 36 provided in the base 30A. Connection portions 320 connected to the electrode portions 16 are formed on upper surfaces of the electrode portions 16. A connection terminal 32 for connecting the batteries 40 in parallel is formed in a region on the base 30A in which the connection terminal 32 does not cover the through holes 36. The connection terminal 32 is connected to the connection portions 320 by fusible links 320A straddling the through holes 36.