Battery Protection Circuit With Fusible Solder for Trigger Cell Detection
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Solution Overview
Problem
Existing battery modules face challenges in detecting a trigger cell from which heat propagates without using temperature sensors, leading to difficulties in managing heat propagation and increasing manufacturing costs.
Innovation Solution
A protection circuit module with a substrate, wire, solder, and cover design that includes a metal with a lower melting point to detect and block heat propagation from a trigger cell, utilizing a migration path for vaporized metal and a heat-resistant cover to maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are applied to all battery cells to detect trigger cells, then detection accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts the temperature sensing function from dedicated temperature sensors and implements it through the existing wire structure. The wire includes a low-melting-point metal segment that melts at a specific temperature to detect thermal conditions, eliminating the need for separate temperature sensors on each battery cell while maintaining detection capability.
Solution Approach 2:
The wire structure is designed to serve multiple functions: electrical connection and temperature detection. By incorporating the low-melting-point metal into the wire, the same component performs both electrical conduction and thermal sensing, reducing the total number of components and manufacturing complexity.
2Reliability
If temperature sensors are applied to all battery cells to detect trigger cells, then heat propagation management is improved, but device complexity increases
Solution Approach 1:
The patent extracts the temperature sensing function from dedicated temperature sensors and implements it through the existing wire structure. The wire includes a low-melting-point metal segment that melts at a specific temperature to detect thermal conditions, eliminating the need for separate temperature sensors on each battery cell while maintaining detection capability.
Solution Approach 2:
The wire structure is designed to serve multiple functions: electrical connection and temperature detection. By incorporating the low-melting-point metal into the wire, the same component performs both electrical conduction and thermal sensing, reducing the total number of components and manufacturing complexity.
3Measurement precision
If a low-melting-point metal is used in the wire to detect heat, then trigger cell detection capability is improved, but wire structural integrity may worsen
Solution Approach 1:
The patent applies local quality by creating a localized low-melting-point metal segment within the wire rather than making the entire wire from low-melting-point material. This segment acts as a thermal indicator while the rest of the wire maintains its original high-strength, high-conductivity material properties, preserving overall wire integrity.
Solution Approach 2:
The wire is designed as a composite structure combining different materials: a low-melting-point metal segment for thermal detection and high-strength, high-conductivity material for the remainder of the wire. This composite approach allows the wire to simultaneously achieve thermal sensitivity and mechanical strength.
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
Enables detection of a trigger cell without temperature sensors, reducing manufacturing costs while effectively blocking heat propagation and ensuring safety performance.
Implementation Method 1
a solder including a second metal having a melting point lower than a melting point of the first metal
Implementation Method 2
provides a migration path for vaporized second metal upon vaporization of the second metal
Implementation Method 3
a cover forming at least one hole and covering at least a portion of the solder
Implementation Method 4
a solder including a second metal having a melting point lower than a melting point of the first metal and the second metal being inserted into at least a portion of the opening to join ends of the wire separated by the opening
Data Source
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AI summary
Disclosed are a protection circuit module and a battery module capable of detecting a trigger cell in which heat propagation occurs within the battery module, even when heat propagation occurs in a battery cell that does not have a temperature sensor. The protection circuit module includes: a substrate; a wire disposed on the substrate to form an opening in at least a portion of the wire and the wire including a first metal; a solder including a second metal having a melting point lower than a melting point of the first metal and the second metal being inserted into at least a portion of the opening to join end of the wire separated by the opening; and a cover forming at least one hole and covering at least a portion of the solder.