Battery Module Busbar Layout With Low-Melting Fuse Sections
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Solution Overview
Problem
Existing busbar designs in battery modules suffer from reduced current carrying capacity and increased internal resistance due to the incorporation of fuse structures, which are necessary for short-circuit protection, leading to inefficiencies in current transmission.
Innovation Solution
A busbar design featuring conductors with integrated fuse parts having a lower melting point than the bar and conducting parts, allowing for current bypass without affecting the current carrying capacity, and arranged to ensure early fusion in case of abnormal conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuse structure is arranged between the positive electrode conducting part and the negative electrode conducting part to meet the fusing requirement of the busbar, then the short-circuit protection function is improved, but the current carrying capacity of the busbar is reduced and internal resistance increases
Solution Approach 1:
The conductor is segmented into three distinct parts: the bar part (main current carrying component), the fuse part (protection component), and the conducting part (connection component). This segmentation allows each part to perform its specific function independently - the bar part maintains high current carrying capacity while the fuse part provides short-circuit protection without compromising the overall busbar performance
Solution Approach 2:
The fuse function is extracted as a separate, dedicated component (fuse part) with distinct material properties (lower melting point), rather than incorporating the fuse structure into the main current carrying path. This extraction allows the main busbar structure to maintain optimal electrical properties while the separate fuse part provides protection functionality
2Reliability
If the melting point of the fuse part is lower than the bar part and conducting part, then the fusing requirement is met and short-circuit protection is achieved, but the current carrying capacity is reduced
Solution Approach 1:
Different parts of the busbar are assigned different material qualities - the bar part and conducting part use materials with high melting points for current carrying, while the fuse part uses material with lower melting point for protection. This local differentiation of material properties allows each region to optimize its function without compromising the whole system's current carrying capacity
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 maintains high current carrying capacity and reduces internal resistance by ensuring fuse parts meet fusing requirements without impacting the busbar's current capacity, enhancing the reliability and efficiency of the battery module.
Implementation Method 1
the fuse part has a melting point lower than a melting point of the bar part and lower than a melting point of the conducting part
Data Source
AI summary
The application provides a busbar and a battery module, which relate to the technical field of battery. The busbar includes a bar part and a plurality of conductors arranged at intervals. Each of the plurality of conductors includes a fuse part and a conducting part. The fuse part has a melting point lower than a melting point of the bus bar and lower than a melting point of the conducting part. Two ends of the fuse part are respectively connected to the conducting part and the bar part. The conducting part is configured to be connected to a positive electrode or a negative electrode of a battery cell.