Battery Pack Module Segmentation with Fuse-Based Power Cutoff
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Solution Overview
Problem
Large-capacity battery packs used in electric and hybrid vehicles face safety risks due to potential electrical shocks and fires from insulation breakdowns or submergence, as existing systems lack effective mechanisms to quickly disconnect power and prevent damage to battery cells.
Innovation Solution
Incorporating a battery control unit connected to first fuses and sensing units, such as airbag impact sensors, to cut off electrical connections between battery modules when damage is sensed, using power cutoff units that generate pressure or heat to disconnect the modules and reduce voltage to a safe level, and optionally including interlock circuits for selective fuse control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large-capacity battery pack is configured by electrically connecting multiple battery modules to increase power and capacity, then the power and capacity are improved, but the risk of electrical shock and fire increases due to potential insulation breakdown or submergence
Solution Approach 1:
The battery pack is divided into multiple battery modules that can be independently disconnected. First fuses are positioned between battery modules to enable segmentation of the electrical system, allowing isolation of damaged modules while maintaining operation of undamaged modules.
Solution Approach 2:
First fuses act as intermediary components between battery modules. These fuses can be selectively activated to interrupt electrical connections between modules, serving as a protective mediator that prevents harmful electrical propagation while allowing normal operation.
2Reliability
If first fuses are positioned between battery modules and connected to the battery control unit to enable quick disconnection, then the safety is improved, but the device complexity increases due to additional control circuits and sensing units
Solution Approach 1:
The battery control unit is designed to perform multiple functions: normal battery management and emergency fuse activation. The sensing units serve dual purposes of monitoring battery status and detecting damage conditions, reducing the need for separate dedicated safety systems.
Solution Approach 2:
The control functions for battery management and safety protection are merged into a single battery control unit. The sensing units are integrated with the control unit, combining monitoring and response functions to reduce overall system complexity while maintaining safety.
3Speed
If the battery control unit transfers signals to first fuses to cut off electrical connections quickly, then the response speed is improved, but the loss of time for battery repair and maintenance increases
Solution Approach 1:
The battery pack is segmented into modular units with individual first fuses between modules. This segmentation allows quick isolation of damaged modules without requiring shutdown or repair of the entire battery pack, enabling faster maintenance response.
Solution Approach 2:
Damaged battery modules can be quickly disconnected and replaced without affecting other modules. The first fuses enable rapid discarding of faulty modules and recovery of system operation using remaining healthy modules, reducing overall downtime.
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 reduces the risk of electrical shocks and fires by quickly disconnecting power between battery modules, improving the safety of the battery pack by maintaining the output voltage at a safe level even if insulation is broken, thus protecting against damage and enhancing safety in electric and hybrid vehicles.
Implementation Method 1
Pressure or heat may be generated in the power cutoff unit by the signal transferred from the battery control unit
Data Source
AI summary
A battery pack including: a plurality of battery modules, each including a plurality of battery cells arranged in a direction; at least one first fuse between battery modules of the plurality of battery modules; a battery control unit connected to the at least one first fuse; and at least one sensing unit connected to the battery control unit, the battery control unit being configured to transfer a signal received from the at least one sensing unit to the at least one first fuse, and the at least one first fuse including a power cutoff unit at a region of a connection member connecting the battery modules to each other, and a case surrounding the power cutoff unit.