Method of making fusible links
First Claim
1. A method of fabricating a fusible link comprising:
- selectively etching, at least in part, a clad foil including a plurality of layers to remove a first layer of a first material to define each of;
a first portion of the clad foil; and
a second portion of the clad foil; and
selectively etching, at least in part, the clad foil to remove a second layer of a second, different material to define a third portion of the clad foil, wherein the third portion couples together the first portion to the second portion to fabricate the fusible link.
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Accused Products
Abstract
Methods of fabricating the fusible link are directed to processing a multi-layer clad foil having a first layer suitable for forming a fusible link and a second layer suitable for forming one or more welding tabs. In some embodiments, the first layer is an aluminum layer and the second layer is a nickel layer. A two-step etching process or a single step etching process is performed on the clad foil to form an etched clad foil having multiple tabs made of the second layer and connected to the current collector conductor pads and battery cell conductor pads, and one or more connections made of the first layer that form aluminum conductors. The aluminum conductors are shaped and sized to form aluminum fusible conductors during either the etching process or a subsequent stamping process. A single fusible link or an array of fusible links can be formed.
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Citations
17 Claims
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1. A method of fabricating a fusible link comprising:
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selectively etching, at least in part, a clad foil including a plurality of layers to remove a first layer of a first material to define each of; a first portion of the clad foil; and a second portion of the clad foil; and selectively etching, at least in part, the clad foil to remove a second layer of a second, different material to define a third portion of the clad foil, wherein the third portion couples together the first portion to the second portion to fabricate the fusible link. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method of fabricating a plurality of fusible links from a clad foil sheet, each fusible link comprising:
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selectively etching, at least in part, the clad foil sheet including a plurality of layers to remove a first layer of a first material to define each of; a first portion of the clad foil sheet; and a second portion of the clad foil sheet; selectively etching the clad foil sheet to remove a second layer of a second, different material to define a third portion of the clad foil sheet that couples together the first portion to the second portion; and forming a fusible conductor from the third portion to fabricate the fusible link. - View Dependent Claims (15, 16, 17)
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Specification