Integrated Solid State Switch Busbar for Battery Systems

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Solution Overview

Problem

Conventional busbars in battery systems face issues with high power dissipation, limited switching times, and increased space requirements due to the use of electromechanical switches and MOSFET-based solid state switches, which also incur additional costs and reliability concerns.

Innovation Solution

A busbar with an integrated solid state switch comprising multiple FETs, where the drain contact is on one surface and the source and gate contacts are on the opposite surface, structurally and electrically integrated into the busbar, allowing for fast switching and reduced power dissipation, and is designed to be compact and robust.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an electromechanical switch and fuse are used for protection, then safety shutdown functionality is achieved, but device complexity and space requirements increase

Engineering Contradiction:

Improvesafety shutdown functionalityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent integrates the protection circuit directly into the busbar structure, merging the protective functionality with the existing electrical connection component. This eliminates the need for separate electromechanical switches and fuses, reducing device complexity while maintaining safety shutdown functionality through electronic protection circuits.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces electromechanical switches with electronic protection circuits integrated into the busbar. This substitution eliminates mechanical moving parts, reducing complexity and improving reliability while achieving the same safety shutdown function through electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If an electromechanical switch is used, then safety shutdown is achieved, but continuous power consumption occurs

Engineering Contradiction:

Improvesafety shutdownVSAvoidcontinuous power consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the electromechanical switch with an electronic protection circuit that consumes power only during active protection events rather than continuously. This substitution uses electronic components that can maintain readiness state with minimal power consumption compared to the continuous power required by electromechanical actuators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a relay-based electromechanical switch is used, then protection function is achieved, but switching time is limited due to mechanical inertia

Engineering Contradiction:

Improveprotection functionVSAvoidswitching time

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

The patent replaces the electromechanical relay with an electronic protection circuit that achieves protection switching without mechanical moving parts. This eliminates the inertia limitation, enabling significantly faster switching times as electronic components can respond much more quickly than mechanical systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Speed

If MOSFET-based solid state switches are used, then switching speed is improved, but power dissipation increases

Engineering Contradiction:

Improveswitching speedVSAvoidpower dissipation

Core Design Contradiction:

SpeedVSLoss of energy

Solution Approach 1:

The patent integrates the solid state switch directly into the busbar structure, merging the switching function with the electrical connection component. This integration optimizes the thermal management by utilizing the busbar's inherent heat dissipation capabilities, reducing power dissipation issues while maintaining fast switching performance.

Inventive Principle:

Principle #5Merging (Combining)

5Reliability

If separate protection components are used, then protection functionality is achieved, but installation space increases

Engineering Contradiction:

Improveprotection functionalityVSAvoidinstallation space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent integrates the protection circuit into the busbar structure itself, merging multiple functions (electrical connection and protection) into a single component. This eliminates the need for separate protection components and their associated mounting space, significantly reducing the overall installation footprint.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3327825B1Busbar for a battery system

Publication Date: 2019.10.02 SAMSUNG SDI CO LTD

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AI summary

The present invention refers to a busbar (100) for a battery system, comprising a first bar element (10) and a second bar element (20) spaced apart, a third bar element (30) connecting the first bar element (10) and the second bar element (20) to form a common bar, a first terminal (12) arranged in the first bar element (10), and a second terminal (22) arranged in the second bar element (20). The busbar (100) is characterized in that the busbar (100) further comprises a solid state switch (40) which is structurally and electrically integrated into the busbar (100), the solid state switch (40) being adapted to electrically interconnect the first terminal (12) and the second terminal (22).