Fusible Link in Battery Voltage Sensing Circuit
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Solution Overview
Problem
Current battery management systems in electric vehicles are prone to failure in extreme environmental conditions and unreliable in certain configurations, as existing safety features such as fuses and protection circuit boards are not effectively integrated into the voltage sensing lines, leading to potential overheating, pressure surges, and current surges.
Innovation Solution
Integrating fusible links directly into the printed circuit boards or flexible circuits connecting battery modules to the battery management system, which are designed to melt and disconnect in case of overcurrent, providing an integrated overcurrent protection feature without adding thickness or requiring additional assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fuses and protection circuit boards are used for overcurrent protection, then protection function is provided, but device complexity and assembly steps increase
Solution Approach 1:
The patent integrates the fusible link directly into the printed circuit board trace, merging the protection function with the existing circuit structure. This eliminates separate fuses and protection circuit boards, reducing device complexity while maintaining overcurrent protection reliability through the integrated fusible link that melts to break the circuit path.
Solution Approach 2:
The printed circuit board trace serves dual functions: normal electrical connection and overcurrent protection. The fusible link portion of the trace acts as both a conductor and a protective element, providing multi-functionality that reduces the need for additional dedicated protection components.
2Reliability
If traditional fuses and protection devices are added to battery modules, then safety features are provided, but manufacturing complexity and assembly steps increase
Solution Approach 1:
The safety function is merged into the printed circuit board manufacturing process itself. The fusible link is created as part of the standard PCB trace fabrication, eliminating separate assembly steps for installing fuses and protection devices, thereby improving ease of manufacture while maintaining safety reliability.
Solution Approach 2:
The protective fusible link structure is prepared in advance during PCB fabrication. The trace is designed with controlled cross-sectional dimensions that pre-determine its melting characteristics, so no additional preparation or assembly steps are needed during battery module manufacturing.
3Reliability
If fusible links are integrated into printed circuit boards, then overcurrent protection is provided without adding thickness, but manufacturing precision requirements increase
Solution Approach 1:
The fusible link portion of the trace is designed with locally different cross-sectional dimensions compared to the rest of the trace. This local quality change creates a controlled weak point that melts at a lower current threshold, providing overcurrent protection while maintaining standard PCB manufacturing processes. The local variation in trace geometry is precisely controlled during fabrication.
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 solution enhances reliability by providing robust, thin, and fire-resistant overcurrent protection within the circuit, preventing damage to adjacent traces and improving safety in high-temperature, high-humidity environments, and various battery cell arrangements.
Implementation Method 1
the fusible link portion including a controlled cross-sectional area in the electrical trace configured to melt at a predetermined electrical current and break the electrical trace
Data Source
AI summary
Devices and systems are provided that incorporate fusible links within the electrical traces of a battery module voltage sensing circuit. The fusible links can be integrally formed in an electric trace and provide an overcurrent protection feature for the circuit without requiring fuse elements or components that are separate from the electrical trace. Each of these fusible links include a substantially flat controlled cross-sectional area disposed along a length of the material making up the electrical trace. In an overcurrent situation, the connection between a battery management system and a battery cell may be severed by the overcurrent melting the fusible link. The electrical traces may be spaced apart from one another in the circuit such that an overcurrent situation breaking the connection between one cell and the battery management system would not affect adjacent electrical traces not having an overcurrent situation.