Battery Module Fusing Portion Insulating Sheet Arc Prevention
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Solution Overview
Problem
The existing power battery systems lack a fuse function in the electrical connections between mono-batteries, leading to hazardous large currents that can cause electrical arcs and potentially result in damage or fire when the arcs are not extinguished.
Innovation Solution
A battery module design that includes an electrical connection sheet with fusing portions between adjacent electrode terminals, supported by an insulating sheet that drops into the fracturing slit to electrically isolate the sides and prevent electrical arcs when a fuse is formed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuse function is added to electrical connection sheet between mono-batteries, then safety against large current is improved, but electrical arc may occur at fracturing slit causing damage
Solution Approach 1:
An insulating sheet is introduced as an intermediary element positioned at the fracturing slit of the electrical connection sheet. When the fusing portion melts and forms a fracturing slit, the insulating sheet drops into the slit to fill it, preventing electrical arc between the positive and negative electrode terminals. This intermediary component resolves the contradiction by maintaining the protective fuse function while eliminating the harmful electrical arc effect.
2Ease of operation
If electrical connection sheet is used to connect electrode terminals, then electrical connection is achieved, but no fuse function is provided for safety
Solution Approach 1:
The patent merges two functions into a single component: the electrical connection function and the fuse protection function. The electrical connection sheet is designed with specific fusing portions that have lower melting points than the electrode terminals. When excessive current flows, these fusing portions melt first to break the circuit, providing both electrical connection during normal operation and fuse protection during abnormal conditions, thereby resolving the contradiction between ease of connection and safety reliability.
3Reliability
If fusing portion is positioned between adjacent electrode terminals, then fuse function is provided, but fracturing slit may be narrow causing electrical arc
Solution Approach 1:
The insulating sheet serves as a mediator that addresses the narrow fracturing slit problem. When the fusing portion melts and creates a narrow fracturing slit between adjacent electrode terminals, the insulating sheet drops into this narrow space to fill it, effectively widening the electrical gap and preventing arc formation. This resolves the contradiction by maintaining the compact fuse design while eliminating the harmful effect of narrow slits.
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 electrical arcs and extinguishes them, ensuring safety by isolating the fused electrical connection sheet and preventing damage to the battery module during hazardous events like short circuits.
Implementation Method 1
the fusing portion of the electrical connection sheet is fused to form the fracturing slit
Implementation Method 2
the insulating sheet supported on the fusing portion drops into the fracturing slit
Implementation Method 3
the insulating sheet drops into the fracturing slit to electrically isolate the two facing sides of the electrical connection sheet
Data Source
AI summary
The present disclosure provides a battery module, which comprises: a plurality of mono-batteries, each mono-battery has electrode terminals which are opposite in electrical polarity; and an electrical connection sheet connecting at least two corresponding electrode terminals, the electrical connection sheet is formed with at least one fusing portion, each fusing portion is positioned between two adjacent electrode terminals. The battery module further comprises: an insulating sheet supported on the fusing portion which is positioned between the two adjacent electrode terminals connected by the electrical connection sheet, when the fusing portion supporting the insulating sheet is fused and a fracturing slit is formed, the insulating sheet drops into the fracturing slit to electrically isolate two facing sides of the electrical connection sheet which are at the fracturing slit. Therefore it avoids the phenomenon of an electrical arc occurring at the fracturing slit and makes the electrical arc extinct.