Battery Pack Overcurrent Protector with Integrated Fuse Connector
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Solution Overview
Problem
Existing battery packs for hybrid cars lack an effective overcurrent protector that prevents damage from short circuits and overcurrents, leading to complex structures and vulnerability during assembly, with fuses not adequately protecting individual cells.
Innovation Solution
A battery pack design featuring a simple structure with fuses integrated into connectors between electrode tabs and voltage sensing lines, preventing overcurrents and minimizing the risk of short circuits by connecting positive and negative electrode tabs with a voltage sensing line and placing a fuse in the connector between the battery cell and the voltage sensing line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuses are detached and attached between electrode terminals and connection members to prevent overcurrent, then overcurrent protection is achieved, but the structure becomes complicated and contact parts may separate due to vibration or impact
Solution Approach 1:
The fuse is merged with the connector to form an integrated overcurrent protector. The connector body houses the fuse element internally, combining the electrical connection function and overcurrent protection function into a single component. This eliminates the need for separate fuse attachment between terminals and connection members, simplifying the overall structure while maintaining reliable overcurrent protection.
2Reliability
If fuses are connected to electrode terminals to prevent overcurrent, then overcurrent protection is provided, but the fuse does not protect individual cells when short-circuiting occurs in each cell
Solution Approach 1:
The battery pack is divided into multiple battery cell groups, with each group having its own connector equipped with a fuse. This segmentation allows each fuse to protect only the specific battery cell group it is connected to, enabling cell-level protection. When a short circuit occurs in one cell group, only the corresponding fuse blows, isolating the fault to that specific group while leaving other groups operational.
3Measurement precision
If connectors and voltage sensing lines are used to measure voltages of each electrode cell, then voltage sensing is achieved, but the system is vulnerable to damage during disposition operation and assembly
Solution Approach 1:
The voltage sensing function is merged with the connector structure. The connector includes integrated voltage sensing terminals that directly contact the electrode tabs, eliminating the need for separate voltage sensing lines. This integration protects the voltage sensing function from damage during assembly operations, as the sensing capability is built into the robust connector housing rather than relying on fragile external wiring.
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 damage from overcurrents and short circuits, simplifies the structure, and reduces the risk of damage during assembly, while allowing for miniaturization without additional space requirements.
Implementation Method 1
a fuse interposed between the electrode tabs of the battery cells adjacent to each other and having one side electrically connected to the connection member of the connector and the other side electrically connected to the voltage sensing line
Implementation Method 2
the fuse... preventing overcurrents and minimizing the risk of short circuits
Data Source
AI summary
The present invention relates to a battery pack in which a plurality of unit modules consisting of battery cells are stacked, adjacently or in regular intervals, and electrode tabs are connected in series, and more specifically, to a battery pack including an overcurrent protector capable of preventing damage to each battery cell caused by a battery cell short circuit or overcurrent which flows in from a protection circuit by: connecting positive and negative electrode tabs of the battery cell with a voltage sensing line in order to sense the voltage of each battery cell; and installing a fuse in a connector which is arranged between the battery cell and the voltage sensing line and couples electrode tabs.