Busbar Module Fuse Branch Layout to Contain Fuse Damage
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Solution Overview
Problem
The existing busbar modules for connecting batteries in automobiles are prone to damage when the pattern fuse is fused, leading to potential expansion of damage to other portions.
Innovation Solution
A busbar module design featuring a pattern fuse on the conductive pattern branch portion, surrounded by a pad connection portion filled with resin, which prevents damage from spreading and provides thermal dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pattern fuse is provided in the conductive pattern body, then the fuse function is achieved, but damage may expand to other portions when the fuse is fused
Solution Approach 1:
The conductive pattern is divided into two distinct parts: the conductive pattern body and the conductive pattern branch portion. The pattern fuse is specifically placed in the branch portion, which is a segmented area that can be isolated from the main body. When the fuse blows, the damage is confined to the branch portion and does not propagate to the conductive pattern body or other portions of the circuit board.
Solution Approach 2:
The fuse function is extracted from the conductive pattern body and placed in a separate conductive pattern branch portion. This extraction allows the fuse to operate independently, and when it fuses, the harmful effects are contained within the branch portion rather than affecting the entire conductive pattern body or other circuit components.
2Reliability
If the insulating sheath covers the entire conductive pattern, then insulation is provided, but damage containment is reduced
Solution Approach 1:
The insulating sheath is segmented into two parts: the sheath body covering the conductive pattern body, and the sheath branch portion covering the conductive pattern branch portion. This segmentation allows the insulating sheath to provide necessary insulation while enabling damage containment in the branch portion when the fuse blows, as the sheath structure can be designed to limit the propagation of damage.
3Reliability
If the pattern fuse is provided in the conductive pattern body, then the fuse function is achieved, but the conductive pattern body may be damaged depending on the degree of fusing
Solution Approach 1:
The conductive pattern is segmented into the conductive pattern body and the conductive pattern branch portion, with the fuse located in the branch portion. This segmentation ensures that when the fuse blows, the mechanical and thermal stress is concentrated in the branch portion, protecting the conductive pattern body from damage and maintaining its structural integrity and electrical conductivity.
Solution Approach 2:
The fuse function is extracted from the conductive pattern body and placed in the conductive pattern branch portion. This extraction protects the conductive pattern body from the damaging effects of fuse operation, such as thermal stress and mechanical deformation, while still maintaining the necessary fuse protection function in the branch portion.
Data Source
AI summary
A busbar module includes a plurality of busbars connected to an electrodes of a battery, and a circuit board including a conductive pattern connected to a busbar, and an insulating sheath covering the conductive pattern. The insulating sheath includes a sheath body and a sheath branch portion protruding from the sheath body. The conductive pattern includes a conductive pattern body covered with the sheath body and provided along a longitudinal direction of the sheath body, and a conductive pattern branch portion covered with the sheath branch portion. The busbar is connected to a distal end of the conductive pattern branch portion, and a pattern fuse is provided on the conductive pattern branch portion.