Dissimilar-Metal Electrode Lead With Integrated Current Cutoff
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Solution Overview
Problem
Existing electrode leads for battery modules are structurally unstable, difficult to manufacture, and lack sufficient resistance to external impact and temperature-induced current cutoff.
Innovation Solution
An electrode lead composed of a first metal plate and a second metal plate with lower melting temperature, where the second metal is dispersed and exposed on the surface, allowing it to melt and cut off current when heated to adjust current cutoff temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal bridge is joined to a metal plate by wrapping around the plate edges, then current cutoff function is achieved, but structural stability and impact resistance deteriorate
Solution Approach 1:
The electrode lead is segmented into a metal plate and a metal bridge as separate components. The metal bridge is inserted into a groove on the metal plate surface rather than wrapping around edges, creating a modular structure that maintains structural integrity while enabling current cutoff function.
Solution Approach 2:
A groove structure serves as an intermediary element between the metal plate and metal bridge. This groove accommodates the metal bridge in a fixed position, providing both structural stability and enabling the metal bridge to perform its current cutoff function without compromising the overall structure.
2Adaptability or versatility
If dissimilar metals are joined together, then current cutoff temperature can be adjusted, but manufacturing difficulty increases
Solution Approach 1:
The metal bridge with lower melting point is selectively placed only in the groove region where current cutoff is needed, rather than joining dissimilar metals throughout the entire structure. This localized approach enables temperature adjustment while simplifying manufacturing.
Solution Approach 2:
The metal bridge is designed as a sacrificial component with lower melting point that will melt during overcurrent events. This disposable element approach simplifies the overall structure and manufacturing, as the metal bridge can be easily replaced or is designed to fail safely without affecting the main metal plate.
3Reliability
If a separate fuse is mounted in the battery module, then safety is improved, but cost and volume increase
Solution Approach 1:
The fuse function is merged with the electrode lead structure itself. The metal bridge within the electrode lead serves dual purposes: conducting current during normal operation and acting as a fuse element that melts to interrupt current during overcurrent events. This integration eliminates the need for separate fuse components, reducing volume and cost while maintaining safety.
Solution Approach 2:
The electrode lead is designed with multi-functionality, serving both as an electrical conductor and as a protective fuse element. The metal bridge portion of the electrode lead can melt under overcurrent conditions to provide safety protection, thereby performing multiple functions with a single component structure.
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 electrode lead provides secure current cutoff and high resistance to external impact, reducing manufacturing costs and improving energy density by integrating a fuse-like function without a separate fuse.
Implementation Method 1
a second metal plate, in which a second metal having a lower melting temperature than the first metal is dispersed
Implementation Method 2
in the case in which overcurrent flows in the secondary battery, the part installed on the path of current flowing in the secondary battery is rapidly ruptured, whereby overcurrent is interrupted
Data Source
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AI summary
The present invention relates to an electrode lead made of dissimilar metals and a method of manufacturing the same, and more particularly to an electrode lead including a first metal plate and a second metal plate, wherein a first metal constituting the first metal plate and second metals having a lower melting temperature than the first metal are mixed in the second metal plate in the state in which the second metals are dispersed, and a method of manufacturing the same.