Magnetic Battery Busbar Interface for Fast Pack Isolation
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Solution Overview
Problem
Current battery pack assembly methods are time-consuming and costly, and there is a lack of effective systems for disconnecting and shunting faulty accumulators within a battery pack while ensuring safety and continuity of operation, particularly for high-voltage systems.
Innovation Solution
A magnetic connection/disconnection device using a permanent magnet with an electrically operated chuck and a coil to establish and break mechanical and electrical contact between an accumulator's output terminal and a busbar, controlled by a Battery Management System (BMS) to enable safe and efficient disconnection and shunting of faulty accumulators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mechanical connection methods are used to connect accumulators to busbars, then the connection is mechanically robust, but the assembly time and cost increase significantly
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (screws, clips, or press-fits) with a magnetic field-based connection system. A coil generates a magnetic field that magnetically attracts the busbar to the accumulator terminal, enabling rapid connection without mechanical fasteners. This substitution dramatically reduces assembly time while maintaining connection robustness through controlled magnetic force.
2Adaptability or versatility
If accumulators are permanently connected to busbars, then the electrical connection is continuous, but the ability to disconnect and shunt faulty accumulators is lost
Solution Approach 1:
The patent transforms the static, permanent mechanical connection into a dynamic, controllable magnetic connection. The coil can be energized or de-energized on demand, allowing the magnetic field to be activated or deactivated. This enables the connection to transition between connected and disconnected states, providing adaptability to disconnect faulty accumulators while maintaining electrical connection stability when connected, as the magnetic force provides consistent holding force.
3Loss of time
If magnetic locks are used for connection, then assembly time is reduced, but the risk of thermal propagation in faulty accumulators increases without proper shunting
Solution Approach 1:
The patent introduces a controllable magnetic field as an intermediary between the accumulator terminal and the busbar. This magnetic intermediary allows for rapid connection (reducing assembly time) while also enabling rapid disconnection when thermal runaway is detected. The BMS acts as a control intermediary, detecting thermal conditions and activating the coil to disconnect the faulty accumulator from the busbar, thereby preventing thermal propagation to other accumulators.
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
This solution reduces assembly time and costs, ensures safe and efficient disconnection of faulty accumulators, and maintains the integrity of the battery pack by preventing thermal propagation and ensuring continuous operation.
Implementation Method 1
a magnetic lock comprising a permanent magnet
Implementation Method 2
around which is wound an electrically conductive wire forming a coil (21) intended to generate a magnetic field parallel to the magnetic field of the permanent magnet
Implementation Method 3
at least a first ferromagnetic part, integral with the busbar, forming a closing plate of a magnetic circuit with the magnetic lock, the closed magnetic circuit ensuring a mechanical and electrical connection
Data Source
Figure 1~5
Figure 6A~6B
Figure 7A~8A
AI summary
The invention essentially consists of integrating within an interface adapter (40), a magnetic lock (11) or a magnetic locking plate (15) cooperating with a magnetic lock attached to a busbar, which allows mechanical and electrical connection/disconnection, by magnetic locking/unlocking, between an output terminal (4, 5) of an accumulator (A) and a busbar (B1, B2).