Compound Fuse for Battery Pack Hard Short Protection
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Solution Overview
Problem
Conventional battery packs face challenges in effectively managing hard short events due to the high heat generation and potential damage during fuse activation, which can lead to housing damage and reduced safety.
Innovation Solution
A compound fuse is introduced, composed of two materials where the fusible portion is made from a material with a lower melting point than the rest, configured to create a discontinuity during a hard short event, reducing heat release and preventing housing damage, and potentially reducing the need for mica as a heat shield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional fuse is used in the battery pack, then protection during hard short events is provided, but high heat generation and potential housing damage occur
Solution Approach 1:
The fuse is constructed as a compound fuse comprising a first material (such as copper or copper alloy) and a second material (such as aluminum or aluminum alloy) with different melting points. The second material forms a fuse portion that melts at a lower temperature to interrupt the circuit, while the first material provides structural support and electrical conductivity. This composite structure enables the fuse to achieve reliable protection during hard short events while significantly reducing heat generation and preventing housing damage compared to conventional single-material fuses.
2Temperature
If a compound fuse with lower melting point material is used, then heat release is reduced and housing damage is prevented, but the fuse structure becomes more complex
Solution Approach 1:
The compound fuse is segmented into distinct functional portions: a first material portion providing structural support and electrical conductivity, and a second material fuse portion designed to melt at a lower temperature. This segmentation is achieved through manufacturing processes such as electroplating, cladding, or co-extrusion, where the second material is applied to or integrated with the first material. The segmented structure enables controlled melting at the fuse portion while maintaining overall structural integrity, reducing heat release and preventing housing damage without requiring complex external components.
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 compound fuse effectively interrupts the current path during a hard short event with reduced heat generation, enhancing safety and potentially allowing for a reduction in mica usage within the battery pack.
Implementation Method 1
The fuse portion is configured to establish a discontinuity between the first portion and the second portion during a hard short event. The compound fuse comprises a first material and a second material that has a lower melting point than the first material.
Implementation Method 2
The compound fuse comprises a first material and a second material that has a lower melting point than the first material. The fuse portion is formed from the second material.
Data Source
AI summary
A battery pack includes a battery pack housing, a plurality of battery pack terminals, and a plurality of battery cells supported within the battery pack housing. At least one battery cell includes a battery cell terminal. The battery pack also includes a compound fuse electrically coupled between the battery cell terminal of the at least one battery cell and at least one battery pack terminal. The compound fuse comprises a first material and a second material that has a lower melting point than the first material. The compound fuse includes a first portion electrically coupled to the battery cell terminal, a second portion electrically coupled to the at least one battery pack terminal, and a fuse portion that connects the first portion to the second portion. The fuse portion is configured to establish a discontinuity between the first portion and the second portion during a hard short event.