Multi-Layer Shunt Resistor for Compact Energy Storage
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Solution Overview
Problem
Existing shunt resistors require significant installation space and are not robust enough to withstand mechanical loads, making them inefficient for compact electrical energy storage systems in automotive applications.
Innovation Solution
A compact shunt resistor design with layers arranged in a stacking direction, featuring a copper-nickel-manganese alloy and copper or aluminum layers, which are welded together to reduce installation space and enhance mechanical stability, allowing for efficient current measurement and status detection without projecting beyond the energy storage unit's contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the shunt resistor is designed with traditional single-layer structure, then the manufacturing process is simple, but the installation space requirement is large and mechanical stability is insufficient
Solution Approach 1:
The patent transitions from a traditional single-layer planar structure to a multi-layer stacked configuration, utilizing the vertical dimension (stacking direction) to reduce the footprint in the horizontal plane. This dimensional change allows the shunt resistor to occupy less installation space while maintaining measurement functionality through multiple contact surfaces.
Solution Approach 2:
The shunt resistor is divided into multiple functional layers (first layer, second layer, third layer) with distinct materials and purposes. This segmentation allows each layer to contribute specific properties (electrical conductivity, mechanical stability, contact surface area) while collectively achieving compact dimensions and enhanced performance.
2Volume of moving object
If the shunt resistor uses a compact multi-layer design, then the installation space is reduced, but the mechanical stability under external loads must be ensured
Solution Approach 1:
The patent employs composite material construction with at least three different layers made from different materials. This composite structure combines materials with complementary properties to achieve both compact dimensions and high mechanical stability, allowing the shunt resistor to withstand external mechanical loads while maintaining its reduced footprint.
Solution Approach 2:
By stacking layers in the vertical dimension rather than expanding in the horizontal plane, the design achieves compactness without compromising mechanical strength. The multi-layer configuration provides distributed load-bearing capacity across multiple surfaces, enhancing stability under compressive and shear forces.
3Volume of moving object
If the layers are arranged in stacking direction rather than longitudinal or transverse axis, then the shunt resistor does not project beyond the energy storage unit contour, but the contact surface accessibility must be maintained
Solution Approach 1:
The patent arranges layers in the stacking direction (vertical dimension) to minimize projection in the longitudinal and transverse directions, allowing the shunt resistor to fit within the energy storage unit contour. Simultaneously, the design ensures that contact surfaces remain accessible by optimizing the stacking configuration and providing appropriate contact interfaces.
Solution Approach 2:
The multi-layer structure creates multiple contact surfaces (first layer contact surface, third layer contact surface) that can be accessed independently. This segmentation of contact interfaces maintains ease of operation despite the compact stacked arrangement, allowing electrical connections to be made at different levels.
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 compact design minimizes installation space requirements, increases mechanical stability, and reduces the risk of failure, enabling reliable and efficient monitoring of electrical energy storage units with reduced installation time and costs.
Implementation Method 1
The shunt resistor is a measuring bridge made of copper/copper-nickel-manganese/copper
Implementation Method 2
which are welded together to reduce installation space and enhance mechanical stability
Data Source
AI summary
The invention relates to a shunt resistor (2) for detecting the status of an electrical energy storage unit (1), wherein the shunt resistor (2) comprises a first layer (4), a second layer (6) and a third layer (8). According to the invention, the layers (4, 6, 8) are arranged in a layered manner in a stacking direction (V), wherein the second layer (6) is arranged between the first layer (4) and the third layer (8), and wherein the layers (4, 6, 8) are in physical contact with one another at one of the sides having the greatest respective surface area, and wherein the layers (4, 6, 8) are arranged at least partially overlapping.