Module Bus Bar Fuse Structure for Shock-Resistant Battery Modules
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Solution Overview
Problem
Existing battery modules face issues with durability due to fuses in bus bars disconnecting prematurely under external shocks or vibrations, leading to potential damage and failure when high currents flow.
Innovation Solution
A battery module design featuring a first metal plate with a thicker body portion facing the module housing and a second metal plate with a thinner body portion, a fuse portion, and a reinforcing portion, along with a cushion member to absorb shocks and a high-specific resistance material to ensure reliable disconnection and increased rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse of the bus bar is formed to have a smaller thickness or width to increase electrical resistance for high current disconnection, then the electrical disconnection capability is improved, but the mechanical stiffness is reduced making the fuse vulnerable to external shocks and vibrations
Solution Approach 1:
The bus bar is divided into three distinct segments: a thick first body portion for mechanical support, a thin fuse portion for electrical disconnection, and a reinforcing portion for structural reinforcement. This segmentation allows each part to optimize its function without compromising the others.
Solution Approach 2:
Different portions of the bus bar have different thicknesses and material properties tailored to their specific functions. The first body portion has larger thickness for stiffness, the fuse portion has smaller thickness for easy disconnection, and the reinforcing portion has increased width for mechanical support. This local differentiation resolves the contradiction between overall strength and localized disconnection capability.
2Speed
If a fuse with smaller dimensions is used to achieve rapid disconnection under high current, then the response speed to overcurrent is improved, but the durability under external shocks and vibrations deteriorates
Solution Approach 1:
The bus bar structure separates the disconnection function (fuse portion) from the structural support function (first body portion and reinforcing portion), allowing rapid disconnection while maintaining overall durability through the reinforced structure.
Solution Approach 2:
The reinforcing portion with greater width than the fuse portion provides pre-reinforcement and mechanical support to the vulnerable fuse area, cushioning it against external shocks and vibrations before damage can occur, while allowing the fuse to still disconnect rapidly when needed.
3Ease of manufacture
If the bus bar uses material with high electrical resistance to improve weldability, then the ease of manufacture is improved, but the electrical efficiency and heat generation worsen
Solution Approach 1:
The bus bar uses different material properties in different regions: the first body portion and reinforcing portion use materials optimized for mechanical strength and low resistance, while the fuse portion uses high-resistance material to enable easy disconnection. This local differentiation allows manufacturing ease where needed without compromising overall electrical efficiency.
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 design enhances durability by maintaining reliable electrical disconnection under high currents and reducing damage from vibrations and impacts, while ensuring rapid fuse activation and improved mechanical stability.
Implementation Method 1
a fuse portion configured to electrically connect the second contact portion and the second body portion to each other and be disconnected at a predetermined current or above, the second metal plate having a smaller thickness than the first metal plate
Implementation Method 2
A battery module design featuring a first metal plate with a thicker body portion facing the module housing and a second metal plate with a thinner body portion, a fuse portion, and a reinforcing portion, along with a cushion member to absorb shocks
Data Source
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AI summary
Disclosed is a battery module including a module bus bar, which may make an electrical disconnection rapidly when a high current flows and has excellent durability. The battery module includes a plurality of cylindrical battery cells having electrode terminals; a module housing having an inner space formed to accommodate the plurality of cylindrical battery cells; and a module bus bar configured to electrically connect the plurality of cylindrical battery cells to each other. The module bus bar includes a first metal plate having a first body portion located to face an outer surface of the module housing and a first contact portion configured to contact the electrode terminal; and a second metal plate having a second body portion stacked on an outer side of the first body portion of the first metal plate, a second contact portion configured to contact the electrode terminal, and a fuse portion configured to electrically connect the second contact portion and the second body portion and be disconnected at a predetermined current or above. The second metal plate has a smaller thickness than the first metal plate.