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.

A fuse element as well as a fuse device and protective device using the same which are capable of suppressing generation of defects such as cracks in a high melting point metal layer, maintaining good conduction, and maintaining blowout properties. The fuse element includes a laminated low melting point metal layer and high melting point metal layer and at least one peak among peaks in an X-ray diffraction spectrum (2) of a surface of the high melting point metal layer has a full width at half maximum of 0.15 degrees or less.

Some embodiments include a fuse having a tungsten-containing structure directly contacting an electrically conductive structure. The electrically conductive structure may be a titanium-containing structure. An interface between the tungsten-containing structure and the electrically conductive structure is configured to rupture when current through the interface exceeds a predetermined level. Some embodiments include a method of forming and using a fuse. The fuse is formed to have a tungsten-containing structure directly contacting an electrically conductive structure. An interface between the tungsten-containing structure and the electrically conductive structure is configured to rupture when current through the interface exceeds a predetermined level. Current exceeding the predetermined level is passed through the interface to rupture the interface.

Some embodiments include a fuse having a tungsten-containing structure directly contacting an electrically conductive structure. The electrically conductive structure may be a titanium-containing structure. An interface between the tungsten-containing structure and the electrically conductive structure is configured to rupture when current through the interface exceeds a predetermined level. Some embodiments include a method of forming and using a fuse. The fuse is formed to have a tungsten-containing structure directly contacting an electrically conductive structure. An interface between the tungsten-containing structure and the electrically conductive structure is configured to rupture when current through the interface exceeds a predetermined level. Current exceeding the predetermined level is passed through the interface to rupture the interface.

The present invention describes a component for a secondary battery and a manufacturing method thereof, and a secondary battery manufactured by using the component. The component for a secondary battery according to the present invention comprises a lead-free soldering bridge having a melting point of 150 to 300 C. and containing tin (Sn) and copper (Cu) as a main ingredient; the first and second metal plates spaced therebetween through a gap and coupling with the lead-free soldering bridge. According to the present invention, when an over-current flows through the component for a secondary battery, the temperature of the lead-free soldering bridge is locally increased rapidly to melt the lead-free soldering bridge, thereby efficiently interrupting the flow of an over-current.

The present invention describes a component for a secondary battery and a manufacturing method thereof, and a secondary battery manufactured by using the component. The component for a secondary battery according to the present invention comprises a lead-free soldering bridge having a melting point of 150 to 300 C. and containing tin (Sn) and copper (Cu) as a main ingredient; the first and second metal plates spaced therebetween through a gap and coupling with the lead-free soldering bridge. According to the present invention, when an over-current flows through the component for a secondary battery, the temperature of the lead-free soldering bridge is locally increased rapidly to melt the lead-free soldering bridge, thereby efficiently interrupting the flow of an over-current.

A fuse element includes a low-melting-point metal plate, a first high-melting-point metal layer, and a second high-melting-point metal layer. The low-melting-point metal plate has a first main surface, a second main surface, a first side surface, and a second side surface. The first main surface and the second main surface face each other. The first side surface and the second side surface face each other and each connect the first main surface and second main surface. The first high-melting-point metal layer is disposed on the first main surface and second main surface. The second high-melting-point metal layer is disposed on the first side surface and second side surface. The fuse element has a cut-out portion in which at least a portion of the second high-melting-point metal layer is cut out.

The invention relates to a fuse element (12_1; 12_2), comprising two connecting contacts (24_1, 24_1; 24_2, 24_2) and an interposed conductive track (26_1; 26_2), wherein the conductive track (26_1; 26_2) has a reduced line-cross-section, in relation, to the connecting contacts (24_1, 24_1; 24_2, 24_2) at least in some sections, further comprising at least one overlay (16_1; 16_2, 16_2), wherein the fuse element (12_1; 12_2) and the overlay (16_1; 16_2, 16_2) each comprise materials which undergo diffusion when a predetermined ambient temperature is exceeded and when an electric current is conducted by the fuse element (12_1; 12_2). The invention further relates to a fuse (TO) having such a fuse element (12_1; 12_2) and a base support (14), wherein the fuse element (12_1; 12_2) is disposed on a surface of the base support (14).

The invention relates to a fuse element (12_1; 12_2), comprising two connecting contacts (24_1, 24_1; 24_2, 24_2) and an interposed conductive track (26_1; 26_2), wherein the conductive track (26_1; 26_2) has a reduced line-cross-section, in relation, to the connecting contacts (24_1, 24_1; 24_2, 24_2) at least in some sections, further comprising at least one overlay (16_1; 16_2, 16_2), wherein the fuse element (12_1; 12_2) and the overlay (16_1; 16_2, 16_2) each comprise materials which undergo diffusion when a predetermined ambient temperature is exceeded and when an electric current is conducted by the fuse element (12_1; 12_2). The invention further relates to a fuse (TO) having such a fuse element (12_1; 12_2) and a base support (14), wherein the fuse element (12_1; 12_2) is disposed on a surface of the base support (14).

Method of manufacturing a high voltage power fuse having a dramatically reduced size facilitated by silicated filler material, a formed fuse element geometry, arc barrier materials and single piece terminal fabrications. The method includes: connecting a full-range fuse element assembly including first and second metal strip fuse elements defining a plurality of weak spots therein and being connected in parallel to one another, the first metal strip fuse element configured to uniquely respond to a short circuit current condition and the second metal strip fuse element configured to uniquely respond to an overload current condition and a set of arc barriers at selected locations to surround respective cross sectional portions are disclosed.