Bus Bar Holder Lead-In Structure for Fused Battery Connections
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Solution Overview
Problem
Existing battery control modules (BCMs) are prone to internal and external short circuits and insufficient to protect the battery management system from undesirable currents, and there is a need for improved methods to quickly and readily connect printed circuit boards (PCBs) to electrochemical cells.
Innovation Solution
A flexible circuit with embedded traces and fuses, a bus bar holder with a lead-in structure, and an electrical conduction assembly that facilitates quick electrical connection and protects against short circuits, using a coating like polyimide to encapsulate fuses and ensure consistent fusing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional PCB configurations are used in BCMs, then the battery management system can perform load balancing and control charging/discharging, but the system is prone to internal and external short circuits and insufficient protection from undesirable currents
Solution Approach 1:
The patent extracts the fuse function from the traditional PCB structure and integrates it directly into the electrical conduction assembly. The fuse is embedded within the bus bar holder structure, separating the protection function from the control circuitry while maintaining integration at the conduction level. This extraction allows the BCM to gain short circuit protection without adding complex external protection circuits.
Solution Approach 2:
The patent merges the fuse with the bus bar holder structure to create an integrated electrical conduction assembly. The fuse is positioned within the holder and electrically connected to the bus bars, combining the current conduction function with the protection function in a single integrated component. This merging reduces the number of separate parts and simplifies the overall BCM structure while improving reliability.
2Productivity
If traditional connection methods are used to connect PCB to electrochemical cells, then electrical connection can be established, but the process is time-consuming and not quick or ready
Solution Approach 1:
The patent implements preliminary action by pre-assembling the electrical conduction assembly with the fuse already integrated into the bus bar holder structure. The bus bars are positioned and secured within the holder before installation, and the fuse is pre-positioned to align with the cell terminals. This preliminary preparation enables quick installation by simply placing the entire assembly onto the battery cells, eliminating time-consuming on-site assembly steps.
Solution Approach 2:
The patent applies the nesting principle by placing the fuse inside the bus bar holder structure. The fuse is nested within the holder's cavity, which also contains the bus bars. This nested arrangement allows multiple components to be integrated in a compact configuration, reducing the overall assembly size and enabling quicker handling and installation of the complete electrical conduction assembly.
3Reliability
If fuses are exposed without encapsulation, then the structure is simpler, but the fusing time is inconsistent and safety is compromised
Solution Approach 1:
The patent uses a coating layer, specifically mentioning polyimide, to encapsulate the fuse. This thin film coating provides protection to the fuse while maintaining its electrical properties. The flexible nature of the coating allows it to conform to the fuse geometry and provides consistent thermal and electrical conditions for reliable fusing operation. This encapsulation enhances safety and fusing time consistency without adding significant structural complexity.
4Ease of operation
If bus bar holder is placed without proper positioning structures, then the structure is simpler, but the holder cannot be quickly and readily placed and maintained over electrochemical cells
Solution Approach 1:
The patent implements preliminary action by incorporating positioning structures (such as alignment features or guide elements) into the bus bar holder during manufacturing. These structures are pre-formed to match the geometry of the battery cell terminals or housing features. This preliminary preparation enables quick and accurate placement of the holder onto the cells without requiring complex alignment procedures or additional positioning tools during assembly.
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 provides enhanced safety and consistency in battery connections by isolating short circuits, preventing cascading failures, and maintaining stable electrical connections in automotive environments.
Implementation Method 1
using a coating like polyimide to encapsulate fuses and ensure consistent fusing time
Implementation Method 2
The traces may further comprise one or more fusable links, which may also be referred to as fuses
Implementation Method 3
an electrical conduction assembly that facilitates quick electrical connection and protects against short circuits
Data Source
AI summary
An electrical conduction assembly comprising a bus bar holder and a plurality of bus bars. The bus bar holder includes a lead-in structure coupled with a main body on a first side. The lead in structure includes a first lead-in wall to be disposed between a first plurality of battery cells and a second lead-in wall orthogonal to the first lead-in wall. The bus bar holder can also include a plurality of pockets, each of which includes a respective aperture and a respective recess. Also disclosed is a battery including the electrical conduction assembly.