Shunt Resistor Protrusions for Stable Current Measurement
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Solution Overview
Problem
Existing shunt resistors for measuring current in secondary battery systems face variability in resistance values due to improper attachment, leading to inaccurate voltage and current measurements, which complicates the diagnosis of battery states.
Innovation Solution
A shunt resistor design featuring protrusions with uneven shapes on its lateral surface, which are bonded with solders to a printed circuit board, ensuring a consistent and accurate electrical connection, thereby stabilizing the resistance value and enhancing measurement reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a banding type shunt resistor is mounted on the PCB with a jig attached on the bottom of the resistor connection body, then the shunt resistor can be connected to the PCB, but the resistance value varies according to attachment locations causing measurement errors
Solution Approach 1:
The invention applies local quality by creating protrusions at specific locations on the shunt resistor body that correspond to precise positions on the PCB printing pattern. This ensures that the connection is made at the optimal location for electrical performance, rather than allowing variable attachment positions. The protrusions concentrate the connection quality at specific local points, ensuring consistent resistance values regardless of minor variations in mounting pressure or alignment.
Solution Approach 2:
The protrusions are pre-formed on the shunt resistor body before mounting, defining the exact connection points in advance. This preliminary action ensures that when the shunt resistor is mounted on the PCB, the connection is made at the predetermined accurate location, eliminating the need for adjustment and ensuring consistent resistance values across different mounting instances.
2Ease of manufacture
If the shunt resistor is connected using a jig and resistor connection body, then electrical connection to the PCB is achieved, but the resistance value is not constant due to attachment location variations
Solution Approach 1:
The protrusions create localized connection points with precise geometry, ensuring that the solder joint is formed at the exact intended location on the PCB. This local quality approach maintains manufacturing simplicity while achieving high precision, as the protrusions guide the solder to the correct position without requiring complex alignment procedures or expensive precision fixtures.
3Reliability
If solders are used to connect the PCB and shunt resistor unit, then electrical connection is established, but without protrusions the connection location is not accurately controlled
Solution Approach 1:
The protrusions concentrate the solder connection at specific localized points, ensuring that the electrical connection is made precisely where intended on the PCB. This local quality approach improves both connection reliability and position accuracy simultaneously, as the protrusions act as mechanical and electrical guides for the solder joint formation.
Solution Approach 2:
The protrusions serve as an intermediary element between the shunt resistor body and the PCB, mediating the connection process. They provide a defined interface that guides the solder to the correct location and ensures consistent electrical contact, thereby improving both connection reliability and positional accuracy without requiring complex external fixtures or alignment procedures.
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 design ensures a stable resistance value, allowing for precise current measurement and improved battery state diagnosis by ensuring a strong and consistent connection between the shunt resistor and the printed circuit board, reducing errors associated with jig-induced resistance variations.
Implementation Method 1
one or more solders connecting the PCB and the shunt resistor unit, and the shunt resistor unit and the PCB may be connected by bonding the one or more solders and the one or more protrusions
Data Source
AI summary
Disclosed is a shunt resistor for measuring current, and a shunt resistor for measuring current, in which one or more protrusions having an unevenness shape, which are formed on one lateral surface of a shunt resistor and one or more solders are bonded to each other, respectively and the shunt resistor and a printed circuit board are electrically connected to each other to measure current of a battery through a shunt resistance included in the shunt resistor unit.