Fusible Switch for Battery Control with Reversible Semiconductor Operation
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Solution Overview
Problem
Current battery management systems fail to effectively address voltage drop and discontinuity of charge/discharge current when faulty battery cells are bypassed, leading to inefficiencies and high power consumption due to on resistance issues in existing fusible switches.
Innovation Solution
A control apparatus and fusible switch design that includes first and second type switches capable of reversible operation, allowing for automatic exclusion of faulty battery cells and inclusion of replacement cells, with a sensing unit and controller to manage switch states, and a fusible switch with a moving electrode and conductive bonding material that minimizes on resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical contact switches are used to bypass faulty battery cells, then the switching function is achieved, but on resistance causes high power consumption and heat generation
Solution Approach 1:
The patent replaces mechanical contact switches with semiconductor-based switches (MOSFETs or IGBTs) to eliminate the on resistance problem inherent in mechanical contacts. The semiconductor switches provide the same bypassing function without the contact resistance that causes power consumption and heat generation, directly resolving the contradiction between reliability and energy efficiency.
2Reliability
If mechanical contact switches are used, then the switching function is achieved, but contact resistance generates excessive heat
Solution Approach 1:
The patent substitutes mechanical contact switches with semiconductor switches that do not rely on physical contact between conductors. This eliminates the contact resistance that generates heat, thereby maintaining the switching function while preventing excessive heat generation during battery cell bypassing operations.
3Reliability
If the contact area between conductors is increased to reduce contact resistance, then contact resistance decreases, but the volume and weight of the switch increase
Solution Approach 1:
The patent replaces mechanical contact-based switching with semiconductor-based switching, eliminating the need to increase contact area or contact pressure to reduce contact resistance. The semiconductor switches achieve low on resistance through their inherent electrical properties rather than mechanical contact, thereby avoiding the weight and volume penalties associated with enlarged mechanical contacts.
4Power
If a large amount of current flows through mechanical contact switches, then the switching function is maintained, but on resistance causes high power consumption
Solution Approach 1:
The patent replaces mechanical contact switches with semiconductor switches capable of handling large currents. The semiconductor switches maintain the high current handling capacity while eliminating the on resistance losses that cause excessive power consumption, enabling efficient operation under high load conditions typical in battery management systems.
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 enables automatic exclusion of faulty battery cells, maintains voltage stability, and reduces on resistance, allowing for compact, lightweight, and reversible operation of the fusible switch, independent of on-current conditions.
Implementation Method 1
a heating element, wherein a melting point of the conductive bonding material is lower than a melting point of the stationary electrodes and a melting point of the moving electrode
Implementation Method 2
the conductive bonding material is melted when heated through the heating element
Data Source
AI summary
A battery control apparatus for a battery according to the present invention excludes a faulty battery cell from the connection between battery cells and at the same time automatically connects a replacement battery cell to the battery cells when a fault occurs in some of the battery cells, thereby allowing the output voltage of the battery to be kept constant in spite of the faulty battery cell. Further, in a state where a plurality of battery modules are connected in parallel, the battery control apparatus disconnects a battery module including a faulty battery cell during the replacement of the faulty battery cell, thereby preventing the output voltage of the battery from being discontinuous. In addition, a switch used in the battery control apparatus for a battery is a fusible switch including two separate fixed electrodes and one movable electrode.


