Fusible Link Design for 18650 Cell Overload Protection
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Solution Overview
Problem
Conventional current overload protection methods for electrical systems, such as batteries with multiple cells, are costly and time-consuming due to the use of fuses, necessitating an improved solution for effectively isolating impacted cells during current overloads.
Innovation Solution
A fusible link system comprising a conductive substrate and terminals with specific structural properties that maintain electrical connections at normal current loads and sever them when exceeding a predetermined maximum, using a conductive substrate with openings and conductors to manage current loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fuses are used for each cell or string of cells to provide current overload protection, then the battery cells can be electrically isolated during current overload, but the manufacturing time increases and procurement costs increase
Solution Approach 1:
The patent combines multiple fuse functions into a single integrated fusible link system with a common conductive substrate that serves multiple battery cells. Instead of installing individual fuses for each cell, the fusible link system provides collective protection across multiple cells through shared substrates and terminals, significantly reducing installation time and complexity while maintaining overload protection capability.
Solution Approach 2:
The conductive substrate and terminal structure are designed to serve multiple functions simultaneously: providing electrical connection points for multiple cells, serving as current pathways, and acting as fusible elements that break under overload conditions. This multi-functional design eliminates the need for separate components for each protection function.
2Reliability
If conventional fuses are used for each cell or string of cells to provide current overload protection, then the battery cells can be electrically isolated during current overload, but the procurement costs increase
Solution Approach 1:
The patent combines multiple fuse functions into a single integrated fusible link system with a common conductive substrate that serves multiple battery cells. Instead of installing individual fuses for each cell, the fusible link system provides collective protection across multiple cells through shared substrates and terminals, significantly reducing installation time and complexity while maintaining overload protection capability.
Solution Approach 2:
The fusible link system uses standardized, repeatable substrate and terminal designs that can be manufactured using consistent processes across multiple units. The modular architecture allows for efficient mass production and standardization, reducing per-unit costs compared to custom individual fuse installations.
3Reliability
If terminals with specific structural properties are used to maintain electrical connection at normal current loads and sever them when exceeding maximum, then current overload protection is achieved, but the device complexity increases
Solution Approach 1:
The terminals are designed with specific structural parameters (cross-sectional area, material composition, length) that determine their melting characteristics. By carefully selecting these parameters, the terminals naturally fuse at predetermined current thresholds without requiring complex control systems or additional components. The structural properties themselves encode the protection logic.
Solution Approach 2:
The terminal structure is designed to automatically respond to overload conditions through self-fusing based on their inherent material and geometric properties. When excessive current flows, the terminals naturally heat up and sever the connection without requiring external detection or control mechanisms. The structure serves its own protection function.
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 fusible link system provides efficient and cost-effective current overload protection by isolating affected cells in batteries, preventing damage while reducing manufacturing time and procurement costs.
Implementation Method 1
Each of the one or more first terminals comprises one or more structural properties configured to maintain an electrical connection with the conductive substrate when a current load on the first terminal is less than a predetermined maximum and sever the electrical connection with the conductive substrate when the current load on the first terminal equals or exceeds the predetermined maximum
Data Source
AI summary
Aspects disclosed herein provide a fusible link system and/or method configured to protect an electrical system/circuit, e.g., a battery comprising a plurality of cells, from a current overload. To that end, the fusible link system comprises a conductive substrate and one or more first terminals that electrically connected to the conductive substrate. Each of the one or more first terminals comprises one or more structural properties configured to maintain an electrical connection with the conductive substrate when a current load on the first terminal is less than a predetermined maximum and sever the electrical connection with the conductive substrate when the current load on the first terminal equals or exceeds the predetermined maximum.