Integrated Cap Plate Fuse for Secondary Battery Safety
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Solution Overview
Problem
Existing secondary batteries face challenges in meeting requirements for high energy density, high output voltage, and stability, particularly in electric vehicles, where conventional fuse designs are limited and difficult to control.
Innovation Solution
A secondary battery design featuring a cap plate with a directly formed fuse part that protrudes and is electrically connected to the electrode assembly, allowing for flexible control of fuse thickness, width, and length, and enabling the formation of multiple small-area fuse parts for secure fixation and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate current collector plate or tab is used for the fuse part, then the fuse part can be electrically connected to the electrode assembly, but the design is limited and difficult to control the dimensions
Solution Approach 1:
The fuse part is merged with the cap plate to form an integrated structure. The cap plate serves dual functions as both a structural component and a current collector with integrated fuse functionality, eliminating the need for separate current collector plates or tabs.
Solution Approach 2:
The cap plate is designed to perform multiple functions simultaneously: it provides structural support, acts as a current collector, and incorporates the fuse part for safety protection. This multi-functional design simplifies the overall battery structure while maintaining all necessary functions.
2Reliability
If the fuse part is formed with larger area, then it provides sufficient current path, but it increases internal resistance and reduces safety
Solution Approach 1:
The fuse part is designed with non-uniform cross-sectional area along its length, with smaller area sections strategically positioned to create controlled weak points. This allows the fuse to have sufficient current-carrying capacity in most sections while having localized areas that will break first under abnormal conditions, optimizing both safety and electrical performance.
Solution Approach 2:
The fuse part is divided into multiple sections with different cross-sectional areas, creating a segmented structure. This segmentation allows different portions to serve different functions: larger sections for current conduction and smaller sections for controlled breaking, optimizing both electrical performance and safety.
3Reliability
If multiple small-area fuse parts are formed, then they firmly fix the electrode assembly and improve safety, but the manufacturing complexity increases
Solution Approach 1:
Multiple fuse parts are integrated into a single cap plate component rather than being separate pieces. This merging of multiple functional elements into one manufacturable component simplifies the assembly process while maintaining the fixation security benefits of having multiple fuse parts.
Solution Approach 2:
The cap plate is designed as a universal component that simultaneously provides structural support, electrical connection, and multiple fuse functions. This multi-functionality eliminates the need for separate manufacturing and assembly steps for individual fuse parts, reducing manufacturing complexity.
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 allowing for easy control of fuse dimensions and formation of small-area fuse parts, improving the battery's ability to handle abnormal conditions like short circuits and overcharging, while reducing internal resistance and component count.
Implementation Method 1
the fuse part electrically connected to the electrode assembly, wherein the fuse part protrudes from the cap plate toward the electrode assembly
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A rechargeable secondary battery (100) includes: a case (110); an electrode assembly (120) accommodated in the case (110); and a cap plate (130) coupled to the case (110) and protecting the electrode assembly (120), wherein the cap plate (130) comprises a fuse part (137) electrically connected to the electrode assembly (120) for protecting the electrode assembly (120) from external short circuiting and overcharge.