PCB Fuse Coating Layout to Prevent Burn Marks and Swelling
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Solution Overview
Problem
In secondary batteries, particularly lithium-ion batteries, fuses on printed circuit boards (PCBs) face issues where high voltage can cause burn marks and decreased insulation resistance due to heat accumulation, leading to potential fires and swelling of conductive patterns.
Innovation Solution
A fuse design featuring a conductive pattern on a PCB with a film and coating, where the film creates an open region and the coating includes a flame-retardant material with a V0 rating, allowing for physical separation and minimizing heat dissipation, thereby preventing burn marks and swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conductive pattern is used on the PCB to accumulate heat, then heat accumulation function is achieved, but burn marks are generated in the upper film and insulation resistance decreases
Solution Approach 1:
The film covering the conductive pattern is divided into multiple regions: a first film region that covers part of the conductive pattern and a second film region that is spaced apart from the conductive pattern. This segmentation allows the film to provide insulation where needed while leaving gaps to prevent burn marks and maintain insulation resistance in high-heat areas.
Solution Approach 2:
Different regions of the film have different properties: the first film region provides insulation coverage over the conductive pattern, while the second film region is positioned away from the conductive pattern to prevent heat-induced damage. This local differentiation allows the film to simultaneously provide insulation and prevent burn marks.
2Reliability
If the film is placed close to the conductive pattern for coverage, then insulation is improved, but the conductive pattern swells up due to gas generated therein when working
Solution Approach 1:
The film is segmented into a first film region covering the conductive pattern and a second film region spaced apart from it. This segmentation creates a gap that prevents gas generated in the conductive pattern from causing swelling, while the first film region maintains insulation coverage.
Solution Approach 2:
The first film region acts as an intermediary between the conductive pattern and the environment, providing insulation coverage. The second film region spaced apart from the conductive pattern serves as a buffer to prevent gas-induced swelling, allowing the conductive pattern to expand without damage.
3Reliability
If the film covers the entire conductive pattern, then insulation resistance is improved, but burn marks are generated and insulation resistance decreases due to heat
Solution Approach 1:
The film is segmented into a first film region that covers part of the conductive pattern and a second film region that is spaced apart from it. This segmentation allows the film to provide insulation where needed while creating gaps to prevent burn marks from heat accumulation.
Solution Approach 2:
Different regions of the film have different coverage properties: the first film region provides insulation coverage over portions of the conductive pattern, while the second film region is positioned away from the conductive pattern to prevent heat-induced burn marks, achieving local optimization of both insulation and heat protection.
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 design effectively prevents burn marks and insulation resistance decrease, stabilizes the conductive pattern, and prevents fires by using a flame-retardant coating and strategically placed open regions, ensuring a stable structure even under high heat conditions.
Implementation Method 1
the coating may include a flame-retardant material... the flame-retardant material may contain a flame-retardant substance of a V0 rating
Implementation Method 2
a conductive pattern disposed on the PCB... in zigzag shapes on the PCB to accumulate heat
Data Source
AI summary
A fuse according to an embodiment disclosed herein includes a printed circuit board (PCB); a conductive pattern disposed on the PCB; a film disposed at lateral sides of the conductive pattern or on a partial region of the conductive pattern to leave an open region; and a coating disposed on the conductive pattern and the film.