Battery Module Fuse Member Design for Short-Circuit Protection

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Solution Overview

Problem

Existing battery modules lack effective mechanisms to prevent extensive damage from overcurrent and abnormal reactions, which can occur due to events like overcharge, penetration, or external short circuits, leading to potential damage across multiple rechargeable batteries.

Innovation Solution

A battery module design that includes a first and second rechargeable battery electrically coupled in series, each with a short-circuit member that deforms to cause a short-circuit when internal pressure exceeds a threshold, and a fuse member with smaller fuses between pads to easily cut off short-circuit current, preventing damage to other batteries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a short-circuit member that deforms when internal pressure exceeds a predetermined pressure is used, then the battery module can respond to internal pressure abnormalities, but the short-circuit current may cause extensive damage to multiple batteries without effective current cutoff

Engineering Contradiction:

Improvesafety response to internal pressureVSAvoiddamage from short-circuit current

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The fuse member acts as an intermediary element between the short-circuit member and the electrode terminals. When the short-circuit member deforms due to internal pressure, it contacts the second pad to complete the circuit, but the fuse member with its smaller width fuses breaks under the resulting short-circuit current, cutting off the harmful current flow before it can damage other batteries

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention converts the harmful short-circuit current into a beneficial protective mechanism. The fuse member is designed with smaller width fuses that are intentionally made to break under short-circuit conditions, transforming the potentially damaging current into a controlled event that triggers automatic circuit isolation and protects the battery module

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Strength

If fuse members with larger pads and wider fuses are used for electrical connection, then the electrical connection is more robust, but the fuse cannot easily cut off short-circuit current

Engineering Contradiction:

Improveelectrical connection strengthVSAvoidshort-circuit current cutoff capability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The fuse member exhibits local quality variation with different width sections serving different functions. The first pad and second pad have larger widths for robust electrical connection and current carrying capacity, while the fuses between them have smaller widths specifically designed to break under short-circuit conditions. This spatial variation in width creates both strong normal operation connections and vulnerable short-circuit protection points

Inventive Principle:

Principle #3Local quality

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

The design enhances safety by effectively cutting off short-circuit currents, minimizing damage to rechargeable batteries and improving stability against abnormal operations, thereby preventing extensive damage to the battery module.

Implementation Method 1

a short circuit member that deforms when an internal pressure of the respective one of the first rechargeable battery and second rechargeable battery exceeds a predetermined pressure

Methodology Applied

Scientific EffectPressure-induced deformation: Deformation

Implementation Method 2

a fuse member including a first pad electrically coupled to the second electrode of the second rechargeable battery, a second pad overlapping the short-circuit member of the second rechargeable battery, and a plurality of fuses formed between the first pad and the second pad

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS10651457B2Battery module

Publication Date: 2020.05.12 SAMSUNG SDI CO LTD

AI summary

A battery module includes a first rechargeable battery and a second rechargeable battery electrically coupled in series to each other, the first rechargeable battery and the second rechargeable battery each including a first electrode and a second electrode, and the first rechargeable battery and second rechargeable battery each including a short circuit member that deforms when an internal pressure of the respective one of the first rechargeable battery and second rechargeable battery exceeds a predetermined pressure, and a fuse member including a first pad electrically coupled to the second electrode of the second rechargeable battery, a second pad overlapping the short-circuit member of the second rechargeable battery, and a plurality of fuses formed between the first pad and the second pad, wherein widths of the fuses are smaller than widths of the first and second pads.