Multi-layered Battery Terminal With Low-melting Fuse
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Solution Overview
Problem
Current traction battery pack designs face challenges in preventing short-circuiting due to cost, weight, and space limitations, as existing methods like electrical fuses and Positive Thermal Coefficient (PTC) washers are not effective for high-power battery cells, and Charge Interrupt Devices (CID) are complex and difficult to implement.
Innovation Solution
The use of multi-layered terminals with conductive segments having a melting point less than adjacent layers, made of materials like indium, which melt to create a gap and prevent sparking, thereby isolating the battery cell and preventing short-circuits, reducing the need for additional fusing and simplifying the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical fuses or PTC washers are used to prevent short-circuiting, then safety is improved, but cost and device complexity increase
Solution Approach 1:
The patent combines the terminal structure with the protective function by integrating a low-melting-point material layer directly into the terminal assembly. This merges the electrical connection function with the short-circuit protection function, eliminating the need for separate fuses or PTC washers and thereby reducing device complexity while maintaining safety
Solution Approach 2:
The terminal assembly performs self-protection through the low-melting-point material that automatically melts when temperature exceeds safe thresholds, creating a gap that interrupts current flow. This self-activating mechanism eliminates the need for external control systems or additional protective components, reducing both complexity and cost
2Reliability
If electrical fuses or PTC washers are used to prevent short-circuiting, then safety is improved, but weight increases
Solution Approach 1:
The protective function is merged into the existing terminal structure, eliminating the need for separate fuse or PTC washer components. This integration removes the additional weight that would be introduced by separate protective devices while maintaining short-circuit prevention capability through the low-melting-point material layer
3Reliability
If CIDs are used to prevent short-circuiting, then safety is improved, but ease of manufacture deteriorates
Solution Approach 1:
The protective function is integrated directly into the terminal manufacturing process by incorporating a low-melting-point material layer during terminal assembly fabrication. This approach is simpler than CID implementation, which requires complex mechanical components and assembly steps, thereby improving ease of manufacture while maintaining safety
Solution Approach 2:
The invention changes the material parameter (melting point) of the terminal layer to enable automatic protection. By selecting a material with a melting point below the short-circuit temperature but above normal operating temperature, the system achieves safety through material property selection rather than complex mechanical or electronic mechanisms, greatly simplifying manufacture
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 effectively prevents short-circuits without adding weight or complexity, is compatible with low-resistance high-power battery cells, and reduces implementation costs by eliminating the need for multiple fuses and complex mechanisms.
Implementation Method 1
Each of the terminals have a plurality of segment layers, and at least one of the segment layers of each of the terminals has a melting point less than that of adjacent segment layers on either side thereof. One of the cells may be electrically isolated from other of the cells in response to at least one of the segment layers of the terminals of the one of the cells melting.
Implementation Method 2
The melting point may be equal to or less than a predefined temperature associated with a short-circuit condition of the cell. The conductive segment may be sized such that, in response to the conductive segment melting, a gap forms between the lower and upper layers sufficient to prevent sparking between the lower and upper layers.
Data Source
AI summary
A vehicle traction battery assembly which may include an array of battery cells is provided. Each of the cells includes terminals of opposite polarity. Each of the terminals may have a plurality of segment layers, and at least one of the segment layers of each of the terminals may have a melting point less than that of adjacent segment layers on either side thereof. One of the cells may be electrically isolated from other of the cells in response to at least one of the segment layers of the terminals of the one of the cells melting. The assembly may also include a housing, and the segment layers having a melting point less than that of adjacent segment layers may be located outside of the housing. The segment layers having a melting point less than that of adjacent segment layers may be located within the housing.