Integrated Fuse Unit Structure for Heat- and Vibration-Protected Connections
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Solution Overview
Problem
The existing conductor units in battery packs for electric and hybrid vehicles are complex and costly due to their numerous components.
Innovation Solution
A simplified fuse unit design comprising a first and second terminal portion connected by a melting portion, covered by a case, with holding portions secured within the case to reduce complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductor unit includes a large number of members (connection conductor, relay terminal, fusible body, resin mold member), then the connection and voltage detection functions are achieved, but the configuration becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent combines multiple separate components (connection conductor, relay terminal, fusible body, resin mold member) into an integrated fuse unit structure. The first and second terminal portions are directly connected through the melting portion, eliminating the need for separate connection conductors and relay terminals, thereby simplifying the configuration while maintaining connection reliability.
Solution Approach 2:
The fuse unit is designed to perform multiple functions within a single integrated structure: electrical connection, voltage detection, and overcurrent protection. The terminal portions provide both mechanical connection and electrical conductivity, while the melting portion serves as both a structural connector and a protective element that responds to overcurrent conditions.
2Reliability
If a conductor unit includes a large number of members (connection conductor, relay terminal, fusible body, resin mold member), then the connection and voltage detection functions are achieved, but manufacturing cost increases
Solution Approach 1:
By merging multiple components into a single integrated fuse unit, the patent reduces the number of parts that need to be manufactured, stored, and assembled. This integration directly reduces manufacturing costs while maintaining the reliability functions through the carefully designed terminal portions and melting portion structure.
Solution Approach 2:
The fuse unit is designed to be a self-contained component that provides all necessary functions (connection, voltage detection, protection) without requiring additional separate components. This self-service design simplifies the overall battery pack assembly and reduces manufacturing complexity.
3Device complexity
If the melting portion is exposed, then the structure is simple, but the melting portion is affected by adverse factors (heat, vibration)
Solution Approach 1:
The patent employs the case as a protective enclosure that shields the melting portion from adverse environmental factors such as heat and vibration. The case acts as a protective shell that maintains structural simplicity while providing necessary protection to the sensitive melting portion.
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 configuration is simplified and manufacturing costs are reduced while protecting the melting portion from adverse effects of heat and vibration, ensuring stable connections and reliable operation.
Implementation Method 1
a melting portion that connects the first terminal portion and the second terminal portion to each other and is configured to melt due to overcurrent
Data Source
AI summary
A fuse unit 10 includes: a first terminal portion 21 to be connected to a bus bar 70; a second terminal portion 31 to be connected to an electric wire 60; a melting portion 41 that connects the first terminal portion 21 and the second terminal portion 31 to each other and is configured to melt due to overcurrent; and a case 50 covering the melting portion 41. The first terminal portion 21 includes a first connection portion 24 having a contact surface 24A that is to come into contact with the bus bar 70, and a first holding portion 23 that is arranged between the first connection portion 24 and the melting portion 41 and is held by the case 50. The second terminal portion 31 includes a second connection portion 34 to be connected to the electric wire 60, and a second holding portion 33 that is arranged between the second connection portion 34 and the melting portion 41 and is held by the case 50.