Series Power Storage Modules with Segmented Fuse and Contactor Protection

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Solution Overview

Problem

The power supply systems in vehicles, comprising multiple series-connected power storage modules, face risks of short-circuit and arc discharge when submerged in water, leading to potential electrolyte leakage and ignition, which existing solutions attempt to mitigate through increased insulation distance or high-spec components, resulting in cost and size inefficiencies.

Innovation Solution

Incorporating a fuse and contactors strategically positioned to divide power storage modules into sub-groups, with a control circuit managing the flow to isolate modules and reduce voltage stress during submersion, utilizing existing components like fuses and contactors to minimize cost and size impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If insulation distance is increased or high specification components are used to enhance withstand voltage, then safety against water infiltration is improved, but system size and cost increase

Engineering Contradiction:

Improvesafety against water infiltrationVSAvoidsystem size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The power supply system is divided into multiple independent power storage modules (first group and second group) separated by a fuse. This segmentation allows the system to limit voltage distribution across modules during submersion, preventing excessive voltage stress on individual cells while maintaining compact overall dimensions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A fuse is introduced as an intermediary component between the first and second groups of power storage modules. The fuse acts as a voltage distribution limiter that prevents direct high-voltage stress on individual modules during submersion, enabling safer operation without requiring increased insulation distances.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If insulation distance is increased or high specification components are used to enhance withstand voltage, then safety against water infiltration is improved, but system cost increases

Engineering Contradiction:

Improvesafety against water infiltrationVSAvoidsystem cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system segments power storage modules into groups with a fuse between them, enabling the use of standard specification components rather than requiring expensive high-withstand-voltage components. This segmentation approach achieves safety through system architecture rather than costly individual component specifications.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fuse serves as a sacrificial, low-cost component that protects the more expensive power storage modules. By using an inexpensive fuse that can be replaced if needed, the system achieves high safety without requiring expensive high-specification components throughout the entire system.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Power

If power storage modules are connected in series to increase voltage, then power output is improved, but risk of short-circuit and arc discharge increases

Engineering Contradiction:

Improvepower outputVSAvoidrisk of short-circuit and arc discharge

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The series-connected power storage modules are segmented into first and second groups separated by a fuse. This segmentation limits the voltage distribution across individual modules during abnormal conditions, reducing arc discharge risk while maintaining high overall voltage and power output capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fuse is pre-installed as a protective measure between power storage module groups. In the event of submersion or short-circuit, the fuse provides beforehand cushioning by limiting voltage stress and preventing catastrophic arc discharge, thereby cushioning the system against harmful effects before they can cause damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS10658853B2Power supply system

Publication Date: 2020.05.19 SANYO ELECTRIC CO LTD

AI summary

In order to reduce costs and increase safety with respect to the submergence of water in a power supply system, in this power supply system (1) a plurality of power storage modules (11)-(14) are connected in series. A fuse (F1) is inserted into the path in which the plurality of power storage modules (11)-(14) are serially connected, the fuse being inserted at a position dividing the plurality of power storage modules (11)-(14) into a first group and a second group. A positive-pole-side contactor (RY1) is inserted at a position dividing the plurality of power storage modules belonging to the first group into a first sub-group and a second sub-group. A negative-pole-side contactor (RY2) is inserted at a position dividing the plurality of power storage modules belonging to the second group into a first sub-group and a second sub-group.