Output Pole Integrated Structure for Stronger Battery Module Fuse Protection
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Solution Overview
Problem
The structural strength and impact resistance of cylindrical power battery modules are compromised due to the limited structural strength of busbars, which are weakened further by the addition of fuse structures, leading to manufacturing complexities, higher costs, and reduced safety in new energy vehicles.
Innovation Solution
The output pole integrated structure, featuring a protective bar with fuse protection, is positioned at the ends of the battery group, allowing for improved structural strength and easier integration of fuse protection, enhancing the overall CCS assembly's impact resistance and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuse structure is arranged on the busbar to provide protection, then safety is improved, but structural strength of the busbar is reduced
Solution Approach 1:
The fuse structure is extracted from the busbar and relocated to the output pole integrated structure. This separation allows the busbar to maintain its structural integrity while the fuse protection function is preserved in a dedicated component with sufficient space and structural capacity.
2Reliability
If fuse structure is formed on the busbar, then protection function is achieved, but manufacturing complexity increases and yield rate decreases
Solution Approach 1:
The CCS assembly is segmented into distinct functional components: the busbar for current distribution and the output pole integrated structure for fuse protection. This modular segmentation simplifies manufacturing by allowing each component to be optimized and assembled separately, reducing overall complexity and improving yield rate.
3Volume of moving object
If busbar structural width and thickness are limited to fit narrow space, then space utilization is improved, but structural strength is reduced
Solution Approach 1:
The fuse structure is taken out from the constrained busbar area and placed in the output pole integrated structure, which has adequate space and structural capacity. This allows the busbar to be designed with optimized dimensions for space utilization while the fuse housing provides the necessary structural strength.
Data Source
AI summary
An output pole integrated structure, a CCS assembly, and a battery module are provided. The output pole integrated structure is arranged at an input end or an output end of a battery group, and includes: an output bar electrically connected to an external device; and a protective bar connected between the output bar and the input end of the battery group, or connected between the output bar and the output end of the battery group. The protective bar is configured to conduct the battery group and the output bar and provided with fuse protection structures.