Method of making fusible links

• US 9,023,218 B2
• Filed: 07/09/2013
• Issued: 05/05/2015
• Est. Priority Date: 11/02/2010
• Status: Active Grant

• Current Assignee: Sinoelectric Powertrain Corporation
• Original Assignee: Sinoelectric Powertrain Corporation
• Inventors: Zhou, Peng, Tsao, Paul
• Primary Examiner(s): Deo, Duy
• Application Number:
  US13/938,136
• Publication Number:
  US 20130293342A1
• Time in Patent Office: 665 Days
• Field of Search: 216/13, 216/41, 216/58, 216/83, 216/100, 296/23, 296/231, 298/25
• US Class Current: 216/13
• CPC Class Codes: H01H 11/00 Apparatus or processes specially adapted for the manufacture of electric switches processes specially adapted for manufacture of rectilinearly movable switches having a plurality of operating members associated with different sets of contacts, e.g. keyboards, H01H13/88
• CPC Class Codes: H01H 2085/025 Structural association with a binding post of a storage battery
• CPC Class Codes: H01H 69/022 of printed circuit fuses
• CPC Class Codes: H01H 85/02 Details
• CPC Class Codes: H01H 85/046 Fuses formed as printed circuits
• CPC Class Codes: H01M 2200/10 Temperature sensitive devices
• CPC Class Codes: H01M 50/534 characterised by the material of the leads or tabs
• CPC Class Codes: H01M 50/536 characterised by the method of fixing the leads to the electrodes, e.g. by welding
• CPC Class Codes: H05K 1/0293 Individual printed conductors which are adapted for modification, e.g. fusable or breakable conductors, printed switches
• CPC Class Codes: H05K 13/00 Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49107 Fuse making
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

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.

Claims

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.

2. The method of claim 1 further comprising forming one or more fusible conductors from the third portion.

3. The method of claim 2 wherein each fusible conductor opens when a current flow through the fusible conductor reaches a predefined threshold current.

4. The method of claim 1 wherein the first layer and the second layer are selectively etched using a single-step etching process.

5. The method of claim 1 wherein the selectively etching to define each of the first portion, the second portion, and the third portions includes:

using a first etchant that etches the first layer but not the second layer; and

using a second etchant that etches the second layer but not the first layer.

6. The method of claim 1 further comprising:

connecting the first portion to a battery cell electrode pad; and

connecting the second portion to a current collector conductor pad.

7. The method of claim 1 further comprising forming the clad foil into a fuse sheet including an array of fusible links, wherein each fusible link is configured to couple to a respective battery cell conductor pad of a battery pack.

8. The method of claim 1 wherein the second layer has a higher melting temperature than the first layer.

9. The method of claim 1 wherein the second layer has a higher electrical resistivity than the first layer.

10. The method of claim 1 wherein the first layer comprises aluminum.

11. The method of claim 1 wherein the second layer comprises nickel.

12. The method of claim 1 further comprising:

welding one or more first portions to respective battery cell conductor pads; and

welding one or more second portions to respective current collector elements.

13. The method of claim 1 wherein selectively etching includes using one or more masks.

14. A method of fabricating a plurality of fusible links from a clad foil sheet, each fusible link comprising:

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.

15. The method of fabricating of claim 14 further comprising, for each of the fusible links:

connecting the first portion to a respective battery cell electrode pad; and

connecting the second portion to a respective current collector conductor pad.

16. The method of fabricating of claim 14 wherein selectively etching includes using one or more masks.

17. The method of fabricating of claim 14 wherein each fusible conductor opens when a current flow through the fusible conductor reaches a predefined threshold current.