Dissimilar-Metal HV Busbar With Integrated Thermal Current Cutoff
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Solution Overview
Problem
Conventional HV busbars face challenges in securely interrupting current flow during abnormal temperature increases and have low resistance to external impacts, making them structurally unstable and difficult to manufacture.
Innovation Solution
A busbar configuration using dissimilar metals with a first metal plate and a second metal plate having a lower melting point, where the second metal plate is dispersed within the first metal plate, exposed on the surface, and contacts the first metal, allowing for controlled current interruption by melting and forming a rupture portion when heated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal bridge with lower melting point is joined to a metal plate to enable current interruption, then current cutoff functionality is achieved, but structural stability and resistance to external impact deteriorate due to dissimilar metal joining difficulties
Solution Approach 1:
The patent combines the current interruption function and structural support function into a single integrated busbar component. The metal plate with embedded lower melting point metal particles serves both as the structural element and the fuse element, eliminating the need for separate metal bridge components and their problematic joints.
Solution Approach 2:
The busbar uses a composite structure where lower melting point metal particles are embedded within a higher strength metal plate matrix. This composite approach allows the lower melting point metal to provide current interruption functionality while the surrounding metal plate provides structural integrity and resistance to external impact.
2Reliability
If a metal bridge is wrapped around the metal plate to join dissimilar metals, then current interruption is enabled, but manufacturing complexity and production difficulty increase
Solution Approach 1:
The invention segments the lower melting point metal into discrete particles that are distributed within the metal plate. This segmentation allows for simpler manufacturing processes such as mixing and casting, compared to the complex wrapping and joining operations required by conventional metal bridge approaches.
Solution Approach 2:
The lower melting point metal particles are directly embedded within the metal plate during manufacturing, allowing the busbar to be self-contained and self-functional. The structure requires no additional assembly steps or external components, thereby simplifying manufacturing and reducing production complexity.
3Reliability
If separate fuses and manual service disconnects are installed for safety, then current protection is achieved, but battery pack volume and manufacturing cost increase
Solution Approach 1:
The busbar is designed to perform multiple functions: electrical connection, structural support, and current interruption protection. By integrating the fuse functionality directly into the busbar, the patent eliminates the need for separate protective devices, thereby reducing battery pack volume and component count.
Solution Approach 2:
The protective fuse function is merged with the electrical connection function in a single integrated component. The metal plate with embedded lower melting point particles serves as both the current conductor and the safety fuse, eliminating the need for separate fuse components and manual service disconnects.
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 high resistance to external impacts, allows for adjustable current cutoff temperature, and serves as a fuse, potentially omitting the need for separate fuses and manual service disconnects, reducing manufacturing costs and improving energy density.
Implementation Method 1
the second metals may have a lower melting point than the first metal... when heated to a predetermined temperature or higher, the second metals may be melted, whereby the sectional area of the second metal plate may be reduced... a rupture portion may be formed in the second metal plate
Data Source
AI summary
An HV busbar configured to connect a plurality of battery modules to each other, has a conductor including a first metal plate and a second metal plate and an insulative resin coating layer on the outer circumferential surface of the conductor, wherein a first metal constituting the first metal plate and second metals having a lower melting temperature than the first metal are mixed in the second metal plate in the state in which the second metals are dispersed.