Shunt Resistor Module Screw Coupling Vibration Protection

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Solution Overview

Problem

Conventional shunt resistor modules in battery packs are prone to lead pin breakage due to poor mounting, vibration, or shock, leading to inadequate current sensing and potential battery pack failures or explosions.

Innovation Solution

A shunt resistor module with an exterior member made of resin injection material, featuring pin holes for lead pin protection and screw holes for secure attachment to a printed circuit board, distributing stress and absorbing vibration shocks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If lead pins are used for electrical connection and mounting, then electrical connectivity is achieved, but the lead pins are prone to breakage due to vibration and shock

Engineering Contradiction:

Improvelead pin durabilityVSAvoidvibration and shock damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an exterior member as an intermediary component between the lead pins and the mounting environment. This exterior member absorbs mechanical stresses from vibration and shock, preventing direct transmission to the lead pins while maintaining electrical connectivity through pin holes that receive the lead pins.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The exterior member serves as a pre-established protective structure that cushions the lead pins against upcoming mechanical stresses. By positioning the exterior member around the lead pins before assembly, the system prepares for and mitigates the harmful effects of vibration and shock before they can cause damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of manufacture

If conventional mounting methods are used, then assembly is simple, but the shunt resistor is poorly mounted leading to lead pin breakage

Engineering Contradiction:

Improveassembly simplicityVSAvoidmounting stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges the mounting function and protective function into a single exterior member structure. The exterior member simultaneously provides mechanical support for stable mounting through screw holes and protection for the lead pins, eliminating the need for separate mounting and protection components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The exterior member appears to be constructed from composite materials or a composite structure combining rigid elements (for mounting stability) and shock-absorbing elements (for lead pin protection), achieving both ease of manufacture and high reliability.

Inventive Principle:

Principle #40Composite materials

3Reliability

If lead pins protrude for electrical connection, then electrical connectivity is enabled, but the lead pins are exposed to mechanical damage

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidmechanical damage to exposed pins

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The lead pins are nested within the exterior member structure, with the exterior member forming a protective cavity or housing that contains the lead pins. The pin holes provide controlled access for electrical connection while the surrounding exterior member material protects the lead pins from lateral mechanical damage.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS11387020B2Shunt resistor module having screw coupling structure

Publication Date: 2022.07.12 LG ENERGY SOLUTION LTD

AI summary

A shunt resistor module which is coupled to a printed circuit board to be used for current measurement, includes: a resistor portion configured to have predetermined resistance; at least two terminal portions configured to extend from opposite ends of the resistor portion; lead pins fixed to first sides of the terminal portions to protrude to be electrically connected to the printed circuit board; and an exterior member formed to at least partially cover first surfaces of the terminal portions and to have pin holes opened to expose the lead pins and screw holes formed to be screwed to the printed circuit board.