Battery Protection Circuit Fuse for Trigger Cell Heat Detection

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Solution Overview

Problem

Existing battery systems face challenges in detecting a trigger cell with increased temperature 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 second metal with a lower melting point than the first metal, allowing detection of a trigger cell and blocking heat propagation without temperature sensors, while reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If temperature sensors are applied to all battery cells to detect trigger cells, then detection accuracy is improved, but manufacturing costs increase

Engineering Contradiction:

Improvedetection accuracyVSAvoidmanufacturing costs

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent extracts the temperature sensing function from dedicated temperature sensors and implements it through the existing fuse structure. The fuse wire itself becomes the temperature detection element, eliminating the need for separate temperature sensors on each battery cell while maintaining detection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fuse structure is given multiple functions: it serves as both a protective device and a temperature sensor. The same component that protects against overcurrent also detects temperature changes in battery cells, reducing the total number of components needed and lowering manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If temperature sensors are applied to all battery cells to detect trigger cells, then heat propagation detection is improved, but device complexity increases

Engineering Contradiction:

Improveheat propagation detectionVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the temperature detection capability from separate sensing devices and integrates it into the fuse structure. This simplifies the overall system by using existing components for multiple purposes rather than adding dedicated temperature sensors to each battery cell.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fuse wire serves itself as a temperature sensor. The physical properties of the fuse wire (resistance, melting point) change with temperature, allowing it to automatically detect temperature changes in battery cells without requiring external sensing mechanisms.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If conventional fuse structures are used without solder and cover, then manufacturing is simpler, but heat blocking capability is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidheat propagation blocking

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent uses a composite structure combining fuse wire, solder material, and cover material. Each layer has specific properties: the fuse wire for current interruption, the solder for thermal management and mechanical bonding, and the cover for heat reflection and containment. This composite approach enhances heat blocking capability while maintaining manufacturability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The solder and cover are pre-installed on the fuse wire before the fuse is activated. This beforehand preparation ensures that when a battery cell overheats, the heat is immediately blocked by the pre-positioned solder and cover structures, preventing heat propagation before it can spread to other cells.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 effective detection and blocking of heat propagation from trigger cells, enhancing safety performance and reducing costs by eliminating the need for temperature sensors in battery modules.

Implementation Method 1

a solder including a second metal having a melting point lower than a melting point of the first metal

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250286253A1Protection circuit module and battery module comprising the same

Publication Date: 2025.09.11 SAMSUNG SDI CO LTD

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.