Battery Pack Bus Bar Rupture Design

The bus bar is designed with a rupture portion that has different properties from the rest of the structure. This rupture portion includes through-holes that reduce its cross-sectional area, making it have lower melting point and lower mechanical strength locally. When overcurrent occurs, this localized weak point melts and ruptures first, protecting the rest of the battery pack while maintaining overall structural integrity through the remaining sound portions of the bus bar.

The rupture portion is segmented by forming multiple through-holes within it, dividing the cross-section into multiple regions. This segmentation reduces the amount of material that needs to melt, accelerates the rupture response time, and distributes the stress concentration points. The segmented structure allows the rupture portion to fail more reliably under overcurrent conditions while maintaining adequate mechanical strength in the unsegmented portions of the bus bar.

The rupture portion is designed as a porous structure with multiple through-holes, which reduces the material density and cross-sectional area in that specific region. This porous configuration accelerates heat penetration and melting during overcurrent events, improving rupture reliability. The through-holes act as heat channels that facilitate rapid temperature rise in the rupture portion, ensuring it fails before other critical components.

The through-holes are strategically positioned within the rupture portion to create localized weak points with reduced mechanical strength. These holes concentrate stress and heat in specific areas, ensuring that the rupture occurs predictably at the intended location. The local quality modification is confined to the rupture portion only, while the rest of the bus bar maintains full mechanical strength for structural support.