Inter-Block Bus Bar Fuse Layout for Vibration-Resistant Battery Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The fuse portion of bus bars in secondary battery modules is prone to breakage due to stress concentration from external forces like vibration or impact, as it is formed thinner or narrower than other portions.
Innovation Solution
A secondary battery module design that includes a holding member with end plates, side plates, and a section plate to reduce stress on the fuse portion of inter-block bus bars, which are strategically positioned near sections of high strength within the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse portion is formed thinner or narrower to enable fuse function, then the fuse portion can protect battery cells from overcurrent, but stress concentration occurs leading to breakage from external forces
Solution Approach 1:
A reinforcing member is introduced as an intermediary element between the fuse portion and the external environment. This reinforcing member has a cross-sectional area larger than the fuse portion and is positioned to overlap with it, absorbing and distributing external stresses (vibration, impact) before they reach the fragile fuse portion, thereby preventing breakage while preserving the fuse's overcurrent protection capability
Solution Approach 2:
The bus bar structure is transformed from a homogeneous single-material component to a composite structure consisting of the bus bar material and the reinforcing member. This composite configuration combines the electrical conductivity and fuse functionality of the bus bar with the mechanical strength and stress-distribution properties of the reinforcing member, resolving the contradiction between fragility and protective function
2Loss of substance
If the fuse portion is formed thinner or narrower, then material usage is reduced, but the fuse portion becomes more susceptible to breakage
Solution Approach 1:
The bus bar system is segmented into functionally distinct components: the fuse portion (thin/narrow for overcurrent protection and material efficiency) and the reinforcing member (larger cross-section for mechanical strength). This segmentation allows each component to be optimized for its specific function while working together as an integrated system
Solution Approach 2:
The reinforcing member acts as a mediator that provides mechanical support to the fuse portion without interfering with its electrical or protective functions. By positioning the reinforcing member to overlap with the fuse portion, it compensates for the reduced material in the fuse area, maintaining reliability while allowing material savings in the critical fuse section
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 design effectively reduces stress on the fuse portion, thereby suppressing breakage due to external forces, while also allowing for a potential reduction in material usage and cost.
Implementation Method 1
When an abnormal overcurrent flows through the bus bar, the fuse portion is allowed to fuse through generation of heat
Data Source
AI summary
A secondary battery module includes a plurality of battery blocks each obtained by stacking a plurality of battery cells. The secondary battery module includes a holding member adapted to hold the plurality of battery blocks and including a pair of opposed end plates, a pair of opposed side plates, and a section plate arranged between the adjacent battery blocks to partition the battery blocks; and an inter-block bus bar provided across the section plate and adapted to electrically connect the adjacent battery blocks. The inter-block bus bar has a fuse portion.