Cell-level fuse

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Current interrupt device

A pressure-activated switch in the cap of a cylindrical cell. When internal pressure rises, usually from overcharge, a disc flips and permanently breaks the current path, removing the cell from the circuit before it vents.

Fuse

A link that melts and opens the circuit when current exceeds its rating. Packs use a main fuse in the high-voltage path and often a small fuse on each parallel cell connection, so one shorted cell does not drain its neighbours into the fault.

Internal short circuit

An unintended electronic path between the electrodes inside a cell — through a metal particle, a burr, a damaged separator or lithium deposits. It discharges the cell internally and turns its energy into local heat.

Prismatic cell

A cell in a rigid rectangular metal case, holding either a flattened jelly roll or stacked sheets. Large prismatic cells pack tightly into battery packs.

Series and parallel connection

Cells in series add their voltages; cells in parallel add their capacities and share current. A pack is described as, for example, 96s4p: 96 groups in series, each of 4 cells in parallel. Series strings need balancing; parallel groups self-balance through their shared terminals.

Wire bonding

Connecting each cell terminal to a busbar or collector plate with a thin aluminium wire, often a few hundred micrometres thick, attached ultrasonically at both ends. The wire can be sized to act as a fuse, so a cell that shorts internally is cut off from its parallel neighbours; Tesla’s cylindrical-cell packs are the best-known example.

References & further reading

Further reading on this topic

These sources provide broader context; they are not presented as citations for every statement in this entry.

1. Thermal runaway mechanism of lithium ion battery for electric vehicles: A review

   Xuning Feng et al. · Energy Storage Materials · 2018

   Topic background · Electrical, mechanical and thermal abuse; thermal-runaway mechanisms and propagation.