Film-Type Cable Fuse Pattern for Overcurrent Blocking

Solution Overview

Problem

The existing film-type cables for cell voltage sensing in vehicle battery modules require separate surface-mount device (SMD) fuses, increasing costs and defect rates due to complex mounting processes and material costs.

Innovation Solution

A film-type cable with a fuse pattern section that is thinner and designed to break when an overcurrent flows, eliminating the need for an SMD fuse, using silver nano ink printed on a base film with a smoke-proof coating to prevent scattering and smoke emission, and alternating fuse pattern sections for effective overcurrent blocking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate SMD fuses are mounted on sensing lines, then overcurrent protection function is achieved, but material cost and processing cost increase

Engineering Contradiction:

Improveovercurrent protection functionVSAvoidprocessing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fuse function is merged into the FPCB itself by forming a fuse pattern directly on the FPCB substrate using conductive material. This integration eliminates the need for separate SMD fuse components and their mounting processes, thereby reducing material cost and processing cost while maintaining overcurrent protection functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The FPCB is designed to serve multiple functions: it acts as both the sensing line carrier and the fuse component. By incorporating the fuse pattern into the FPCB structure, the cable achieves both signal transmission and overcurrent protection functions through a single component, reducing overall system complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate SMD fuses are mounted on sensing lines, then overcurrent protection function is achieved, but defect rate increases

Engineering Contradiction:

Improveovercurrent protection functionVSAvoiddefect rate

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The fuse function is merged into the FPCB itself by forming a fuse pattern directly on the FPCB substrate using conductive material. This integration eliminates the need for separate SMD fuse components and their mounting processes, thereby reducing material cost and processing cost while maintaining overcurrent protection functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The FPCB is designed to serve multiple functions: it acts as both the sensing line carrier and the fuse component. By incorporating the fuse pattern into the FPCB structure, the cable achieves both signal transmission and overcurrent protection functions through a single component, reducing overall system complexity and cost.

Inventive Principle:

Principle #25Self-service

3Reliability

If fuse pattern section is made thinner, then fuse function is enabled, but cable strength decreases

Engineering Contradiction:

Improvefuse functionVSAvoidcable strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The FPCB is designed with different thicknesses at different locations: the fuse pattern section is made thinner to enable fuse function, while other sections maintain normal thickness for structural strength. This local differentiation allows the cable to achieve both fuse functionality and adequate mechanical strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The FPCB is divided into different functional sections with different thickness characteristics: fuse pattern sections with reduced thickness for overcurrent protection, and normal sections with full thickness for mechanical support. This segmentation allows each section to be optimized for its specific function.

Inventive Principle:

Principle #1Segmentation

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 solution reduces material and processing costs, ensures reliable fuse function, and prevents smoke and scattering during overcurrent events, enhancing the cable's functionality and cost-effectiveness.

Implementation Method 1

a fuse pattern section provided to be broken when a current exceeding a rated current flows

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

using silver nano ink printed on a base film with a smoke-proof coating to prevent scattering and smoke emission

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS12165790B2Film-type cable including fuse line

Publication Date: 2024.12.10 LG ENERGY SOLUTION LTD

AI summary

A film-type cable according to the present disclosure includes an insulating film and a plurality of conducting wires covered by the insulating film and extending in a first direction, each of the plurality of conducting wires separate by a predetermined distance, wherein each of the plurality of conducting wires includes: a fuse pattern section configured to be broken when a current exceeding a rated current flows through the fuse pattern section; and a normal section configured not to be broken when a current exceeding the rated current flows through the normal section, wherein the fuse pattern section may be thinner than the normal section.