Rechargeable Battery Fuse Terminal Design
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Solution Overview
Problem
Rechargeable batteries face safety risks due to potential overheating and pressure buildup from overcharging or electrolyte decomposition, which can lead to ignition or explosion.
Innovation Solution
Incorporating fuses both inside and outside the battery cell, with the outside fuse designed to melt earlier than the inside fuse during an electric short circuit, redirecting arcing outside the cell to prevent internal breakdown and explosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rechargeable battery is designed with standard electrode terminals and internal structure, then manufacturing simplicity and cost-effectiveness are maintained, but safety risks increase due to potential overheating and pressure buildup from overcharging or electrolyte decomposition
Solution Approach 1:
The electrode terminal is segmented into multiple functional parts: an external terminal portion for electrical connection, an internal fuse portion with controlled cross-sectional area smaller than other terminal parts, and connection portions linking to electrode plates. This segmentation allows the terminal to serve both electrical connection and safety protection functions, preventing short circuits by isolating faulty sections while maintaining overall structural integrity
Solution Approach 2:
The fuse portion is pre-designed with a smaller cross-sectional area than other terminal parts, creating a predetermined weak point that will fail first under abnormal conditions. This preliminary design ensures that when overcharging or short circuit occurs, the fuse portion melts or breaks before other critical components, preventing catastrophic failure of the entire battery system
2Reliability
If the battery structure is kept simple without additional safety components, then manufacturing ease and cost are maintained, but the battery cannot prevent abnormal breakdown or explosion under overcharge or short circuit conditions
Solution Approach 1:
The electrode terminal is designed to perform multiple functions simultaneously: it provides electrical connection between electrodes and external circuits, serves as a structural support element, and acts as a safety fuse mechanism. The terminal's body includes a fuse portion with controlled cross-sectional area that melts under abnormal conditions, eliminating the need for separate fuse components and simplifying manufacturing while enhancing safety
3Reliability
If fuse portions with smaller cross-sectional area are incorporated into electrode terminals, then safety is improved by preventing short circuit propagation, but manufacturing precision requirements increase
Solution Approach 1:
The terminal body exhibits local quality variations, with the fuse portion having a deliberately smaller cross-sectional area compared to other terminal sections. This localized dimensional difference is strategically designed to create a predetermined failure point that melts first under thermal stress, protecting the rest of the battery system while maintaining reasonable manufacturing tolerances through focused precision only where needed
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 enhances safety by minimizing the risk of abnormal breakdown and explosion by ensuring that any arcing generated during a short circuit occurs outside the battery cell, thereby preventing damage and ensuring safer operation.
Implementation Method 1
the first fuse part is surrounded by an insert molding part
Implementation Method 2
the first fuse part is surrounded by an insert molding part
Data Source
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AI summary
A rechargeable battery includes fuses inside and outside a cell, thereby improving safety by preventing abnormal breakdown from occurring in the cell due to an electric short circuit. The rechargeable battery includes an electrode assembly including a first electrode plate, a second electrode plate and a separator between the first electrode plate and the second electrode plate, a case accommodating the electrode assembly, and a first electrode terminal and a second electrode terminal electrically connected to the first electrode plate and the second electrode plate and protruding to the outside of the case. One of the first electrode terminal and the second electrode terminal includes a fuse part.