Battery Module Shorting Member and Fuse Safety Mechanism
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Solution Overview
Problem
High-power rechargeable battery modules face safety risks due to potential combustion or explosion from increased internal pressure or temperature, particularly when gas is generated from the electrolyte solution.
Innovation Solution
Incorporation of a shorting member and a fuse unit within the battery module's connecting members to induce a short circuit or disconnect electrical connections upon overcurrent or increased internal pressure, preventing further charge and discharge reactions that could lead to explosion or combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If rechargeable batteries are coupled in series to form high-power battery modules, then power output is improved, but safety risk increases due to potential combustion or explosion
Solution Approach 1:
The battery module is segmented into multiple independent battery units, each equipped with its own protection circuit. This segmentation allows individual batteries to be monitored and protected separately, preventing a single point of failure from causing module-wide safety issues while maintaining high power output through series connection.
Solution Approach 2:
A shorting member is introduced as an intermediary safety device between neighboring batteries. When abnormal conditions are detected, the shorting member activates to create a controlled short circuit, serving as a mediator that prevents thermal runaway from propagating between batteries while allowing normal operation to continue.
2Reliability
If connecting members are used to electrically connect neighboring batteries, then electrical connectivity is improved, but safety risk increases when overcurrent occurs
Solution Approach 1:
The connecting member is designed with a preliminary safety feature: a fusible section with lower melting point than the main body. This preliminary weak point is intentionally created to fail first under overcurrent conditions, disconnecting the electrical connection before the main connecting member or battery terminals can be damaged, thus protecting the overall electrical connectivity system.
Solution Approach 2:
The connecting member exhibits local quality differentiation with a fusible section having distinct material properties (lower melting point) compared to the main body. This localized property change allows the connecting member to serve dual functions: maintaining electrical connectivity under normal conditions and providing protective disconnection under abnormal conditions.
3Productivity
If battery module continues operation after one battery malfunctions, then productivity is maintained, but safety risk increases due to potential combustion or explosion
Solution Approach 1:
The battery module operates as segmented independent units with individual protection circuits. When one battery malfunctions, the segmentation allows the protection circuit to isolate only the affected battery while maintaining operation of other batteries, thus preserving productivity without compromising safety through controlled isolation.
Solution Approach 2:
The shorting member converts the harmful effect of battery malfunction into a beneficial safety mechanism. When abnormal conditions are detected, the shorting member creates a controlled short circuit that safely dissipates energy and prevents thermal runaway, transforming a potentially dangerous situation into a protected state that allows continued operation of healthy batteries.
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 stops disorderly charge and discharge, enhancing safety by preventing explosions or combustion, allowing the battery module to continue functioning with reduced voltage output even if one rechargeable battery malfunctions, thus preventing sudden vehicle stops in electric or hybrid vehicles.
Implementation Method 1
a fuse unit configured to disconnect the first terminals of the neighboring rechargeable batteries when an overcurrent is generated
Implementation Method 2
a shorting member configured to generate a short circuit by connecting neighboring second connecting members of the plurality of second connecting members to each other
Implementation Method 3
a driver coupled to the shorting plate and configured to move the shorting plate to contact the neighboring connecting members
Data Source
AI summary
A battery module including a plurality of rechargeable batteries including a case and terminals protruding outside of the case; a first connecting member electrically connecting first terminals of neighboring rechargeable batteries and including a fuse unit configured to disconnect the first terminals of the neighboring rechargeable batteries when an overcurrent is generated; a plurality of second connecting members electrically connecting second terminals of the neighboring rechargeable batteries to terminals of connected rechargeable batteries; and a shorting member configured to generate a short circuit by connecting neighboring second connecting members to each other.