Battery module thermal runaway early warning device and battery module
By incorporating a high-temperature fusible fuse in the battery module and utilizing the high-temperature gas fuse circuit when the explosion-proof valve is opened, the problem of delayed early warning for battery thermal runaway is solved, achieving real-time early warning and improved safety.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- 中汽新能(天津)电池科技有限公司
- Filing Date
- 2025-05-21
- Publication Date
- 2026-07-07
Smart Images

Figure CN224472634U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of battery module technology, and in particular to a battery module thermal runaway early warning device and a battery module. Background Technology
[0002] Thermal runaway in power batteries refers to the phenomenon where the battery temperature rises uncontrollably due to a chain reaction of exothermic reactions within individual battery cells. Establishing an early warning mechanism for thermal runaway in power batteries is of great significance for improving the safety of power battery use. Currently, early warning of thermal runaway in power batteries is mainly achieved by monitoring changes in battery parameters, such as temperature and voltage.
[0003] During thermal runaway of a power battery, the following processes occur: decomposition of the SEI film, reaction between the electrolyte and the negative electrode, melting of the separator, decomposition of the positive electrode, decomposition of the electrolyte, decomposition of the binder, and combustion of the electrolyte. Under thermal runaway, complex and violent chemical reactions occur inside the battery. These violent reactions generate a large amount of gas and release a large amount of heat. When the internal pressure of the battery rises to the explosion-proof valve's burst threshold, the rapidly expanding gas, heated, breaks through the explosion-proof valve, resulting in material ejection or even combustion.
[0004] Temperature sensors are commonly used to monitor the occurrence of battery thermal runaway. However, the temperature difference between the inside and outside of the battery will always cause temperature sensors such as thermocouples to fail to respond in time. At the same time, the number of temperature sensors is small and they do not cover every battery. Temperature conduction is delayed, which poses a high safety risk.
[0005] Thermal runaway in a battery can cause a sudden drop in battery voltage. Therefore, monitoring voltage changes is used to warn of the occurrence of thermal runaway. However, the voltage does not drop immediately in the early stages of thermal runaway. The voltage drop occurs after the explosion-proof valve opens. Moreover, thermal runaway is not the only cause of sudden voltage drop in a power battery. Poor contact at internal connections can also cause this phenomenon. Untimely warnings may lead to misjudgments, which also poses a high safety risk.
[0006] Most existing square batteries have their explosion-proof valves located in the middle of the top cover, and there is no effective means of monitoring when the explosion-proof valve opens in the early stages of thermal runaway. Utility Model Content
[0007] The purpose of this invention is to overcome the shortcomings and defects of the existing technology and provide a battery module thermal runaway early warning device and a battery module. This battery module thermal runaway early warning device can react rapidly when the battery explosion-proof valve opens, providing earlier warning of the occurrence of thermal runaway.
[0008] One objective of this utility model is to provide a battery module thermal runaway early warning device, including a flexible circuit board of the battery module and a busbar connecting the battery cells; the flexible circuit board is connected to a conductive connecting piece, and the conductive connecting piece is connected to the busbar through a fuse; the fuse can be melted by the high-temperature gas ejected by the explosion-proof valve when the battery thermal runaway is activated, thereby disconnecting the connection between the conductive connecting piece and the busbar.
[0009] Preferably, the fuse is located above the explosion-proof valves of two adjacent batteries on the large surface / above the explosion-proof valve of the battery cell.
[0010] Preferably, the fuse includes a solder layer formed of tin, lead-tin alloy or bismuth-tin alloy, and the bus connection portion is soldered to the conductive connecting piece through the solder layer, the conductive connecting piece being located below the bus.
[0011] Preferably, the fusion device includes a connector made of an elastic / inelastic polymer material.
[0012] Preferably, the fusion device includes a thermoplastic rivet, the connecting portion of the busbar is in contact with the conductive connecting piece, and the thermoplastic rivet passes through the connecting portion of the busbar and the conductive connecting piece to connect the busbar and the conductive connecting piece.
[0013] Preferably, the fusion device includes an elastic rubber ring, the connecting part of the busbar is in contact with the conductive connecting piece, and the elastic rubber ring is sleeved on the outside of the connection position between the connecting part of the busbar and the conductive connecting piece, thereby securing the busbar and the conductive connecting piece tightly.
[0014] Preferably, the cell explosion-proof valve is biased and arranged close to the positive / negative terminal of the cell.
[0015] Another objective of this invention is to provide a battery module thermal runaway early warning device, comprising a flexible circuit board for the battery module and a busbar connecting the battery cells; the flexible circuit board has an extended ribbon cable, the extended ribbon cable is connected to a conductive connecting piece, the conductive connecting piece is electrically connected to the busbar, and the extended ribbon cable is located above the battery cell explosion-proof valve; the extended ribbon cable includes a metal wire body and a non-metallic film covering the metal wire body; the non-metallic film can be melted by the high-temperature gas ejected by the explosion-proof valve when the battery thermal runaway is activated, so that the metal wire body is exposed and comes into contact with the exposed metal of the battery top cover, forming a short circuit between the battery casing and the busbar, melting the metal wire body, and disconnecting the electrical connection between the flexible circuit board and the busbar.
[0016] Preferably, the metal wire is made of aluminum cable, and the cell explosion-proof valve is biased and arranged close to the positive / negative terminal of the cell.
[0017] The third objective of this invention is to provide a battery module, including a thermal runaway early warning device for the battery module.
[0018] This utility model discloses a battery module thermal runaway early warning device. Its fuse is positioned above or between two explosion-proof valves. In conjunction with the explosion-proof valves, it can disconnect the monitoring circuit formed by the electrical connection between the module's battery cells and the flexible circuit board when the explosion-proof valves open, using the high-temperature gas emitted during the opening. This provides an immediate alarm function based on the opening of the explosion-proof valves, solving the technical problem that existing technologies, which rely solely on parameters such as temperature and voltage to monitor thermal runaway, have a lag and cannot quickly respond to provide early warning when the explosion-proof valves open.
[0019] The battery module thermal runaway early warning device of this utility model has a fuse that can quickly disconnect when the explosion-proof valve is opened in the early stage of thermal runaway, helping the system to identify and warn of the occurrence of thermal runaway; the fuse can quickly warn of thermal runaway after the explosion-proof valve is opened before the battery external temperature rises and the voltage drops sharply due to thermal runaway, thus enabling the system to identify thermal runaway in advance. Attached Figure Description
[0020] Figure 1 This is a schematic diagram of a dual-parallel battery module with a fuse device according to an embodiment provided in this application.
[0021] Figure 2 yes Figure 1 Enlarged view of section A.
[0022] Figure 3 yes Figure 2 A partial schematic diagram of the first busbar and the conductive connector after welding.
[0023] Figure 4 yes Figure 3 Enlarged view of section B.
[0024] Figure 5 This is a schematic diagram of a single cell with an explosion-proof valve biased according to an embodiment provided in this application.
[0025] Figure 6 This is a schematic diagram showing the arrangement of the fuse device in a single-parallel battery module with a fuse device according to an embodiment of this application.
[0026] Figure 7 This is a schematic diagram showing the connection between the second busbar and the conductive connecting piece of an applicable single-parallel module according to an embodiment provided in this application.
[0027] Figure 8 yes Figure 7 A magnified view of part C in the middle.
[0028] Figure 9 This is a schematic diagram of the second busbar and the conductive connecting piece connected by thermoplastic rivets in an embodiment provided in this application.
[0029] Figure 10 yes Figure 9 A magnified view of part D in the middle.
[0030] Figure 11 This is a partial schematic diagram of the busbar and nickel sheet fixing structure provided in this application using an elastic rubber ring.
[0031] Figure 12 yes Figure 11 A magnified view of part E in the image.
[0032] Figure 13 This is a schematic diagram of a dual-parallel battery module with another type of fuse device, according to an embodiment provided in this application.
[0033] Figure 14 yes Figure 13 A schematic diagram of the second flexible circuit board.
[0034] Explanation of reference numerals in the attached figures:
[0035] 1 is the first busbar, 2 is the first conductive connecting piece, 3 is the flexible circuit board, 4 is the battery QR code, 5 is the explosion-proof valve, 6 is the battery, 7 is the solder layer, 8 is the second busbar, 9 is the hot melt rivet, 10 is the elastic rubber ring, 11 is the third busbar, 12 is the second conductive connecting piece, 13 is the second flexible circuit board, 14 is the opening of the top cover insulation sheet around the battery explosion-proof valve, and 15 is the protruding ribbon cable. Detailed Implementation
[0036] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.
[0037] In an exemplary embodiment of this application, a high-temperature fusible fuse is installed above the explosion-proof valve or above the space between adjacent explosion-proof valves to connect the flexible circuit board of the battery module to the busbar of the battery. When the explosion-proof valve is opened, the temperature of the injected gas exceeds 300°C, which melts the fusible fuse, allowing the system to detect the circuit abnormality and immediately warn of thermal runaway.
[0038] Please see Figures 1 to 5As shown in the exemplary embodiment of this application, the battery module thermal runaway early warning device can be used in a battery module with a dual-parallel structure, including a first flexible circuit board 3 of the battery module and a first busbar 1 connecting the battery cells; the first flexible circuit board 3 is connected to a conductive connecting piece 2, and the conductive connecting piece 2 is connected to the first busbar 1 through a fuse device. The fuse device can be melted by the high-temperature gas ejected by the explosion-proof valve 5 when the battery thermal runaway is activated, thereby disconnecting the conductive connecting piece 2 from the first busbar 1, thus disconnecting the monitoring circuit connected to the battery management system and realizing an abnormal alarm.
[0039] In this embodiment of the application, the fuse can eject high-temperature gas to melt and break the battery cell when it experiences thermal runaway. Since the temperature of the high-temperature gas ejected during battery thermal runaway is generally around 300°C, the fuse should be designed to melt at a high temperature of around 300°C. Specifically, the material used for the fuse can be determined based on the temperature of the high-temperature gas ejected during battery thermal runaway as determined by experiments, as well as the experimental melting results.
[0040] In some embodiments, the fuse can be implemented using a solder layer 7 formed of tin (melting point 231.9°C), lead-tin alloy (melting point approximately between 200 and 320°C), or bismuth-tin alloy (melting point approximately 138°C). For example, the first busbar connection is welded to the conductive connecting piece using the solder layer formed of tin, lead-tin alloy, or bismuth-tin alloy, with the conductive connecting piece located below the first busbar. In this embodiment, when the high-temperature gas ejected during battery thermal runaway, the solder layer used for welding can melt, thereby breaking the weld between the first busbar connection and the conductive connecting piece. This disconnects the monitoring circuit connected to the battery management system, enabling an abnormal alarm.
[0041] like Figure 2 As shown, when using solder layer 7 for connection, the fusion device formed by the solder between the conductive connecting piece and the first busbar is located directly above the two battery explosion-proof valves 5, with the first busbar covering the explosion-proof valve. The battery explosion-proof valve is located on the top cover of the battery, and its position is offset. In the initial stage of thermal runaway, after the battery explosion-proof valve opens, the high-temperature gas jet causes the solder joint to melt, disconnecting the first busbar from the conductive connecting piece. The system detects the circuit abnormality and can then trigger a thermal runaway alarm. Experimental testing shows that, taking tin as an example, when the lithium battery explosion-proof valve opens, the gas temperature ejected from the valve port can reach over 300℃. Tin's melting point is 231.9℃; the high temperature can melt the tin, causing the first busbar to disconnect from the nickel plate, resulting in a system circuit abnormality and thus triggering an immediate alarm for thermal runaway after the valve opens.
[0042] In an exemplary embodiment of this application, the battery module thermal runaway early warning device can also be used in a battery module with a single-parallel structure. The single-parallel structure battery module structure in the embodiments of this application is as follows: Figure 6 As shown, the structure of its single cell is described in [reference needed]. Figure 5 As shown, the second busbar 8, whose shape differs from that of the first busbar 1, is connected to the conductive connecting piece 2 in the following schematic diagram. Figure 6 As shown, the fusion device (such as solder layer 7) formed by the solder between the second busbar 8 and the conductive connecting piece 2 is located directly above the center of the battery explosion-proof valve. Figure 6 As shown, in the initial stage of thermal runaway, after the explosion-proof valve opens, high-temperature gas is injected into the connection part, causing the solder layer of the fuse device to melt, and the second busbar and the conductive connecting piece 2 are disconnected. The system detects the circuit abnormality and can then trigger a thermal runaway alarm.
[0043] According to the characteristic requirements of the fuse device, in the embodiments of the above-mentioned single-parallel structure battery module structure of this application, the fuse device can also be made of low melting point metal / non-metal materials, such as metal / non-metal materials with a melting point below 300°C.
[0044] In some embodiments, the fusion device may be a connector made of elastic / inelastic polymer materials, such as PC material (melting point 220°C) / ABS material (melting point 170°C) or elastic rubber.
[0045] In some embodiments, such as Figure 9 , 10 As shown, the fusion device can be a thermoplastic rivet 9 made of the aforementioned material. The connecting part of the second busbar is in contact with the conductive connecting piece. The thermoplastic rivet 9 passes through the connecting part of the second busbar and the conductive connecting piece to connect the second busbar to the conductive connecting piece.
[0046] In this embodiment, the thermoplastic rivet 9 connects the second busbar to the conductive connecting piece. When the high-temperature gas ejected during battery thermal runaway melts through the thermoplastic rivet, the electrical connection between the second busbar and the conductive connecting piece is broken, thereby disconnecting the monitoring circuit connected to the battery management system and triggering an alarm. Thus, when the explosion-proof valve experiences a burst, the high temperature melts the thermoplastic rivet, breaking the connection between the second busbar and the conductive connecting piece 2, causing a circuit malfunction and achieving an early warning purpose.
[0047] In the embodiments of the above-described single-parallel structure battery module structure of this application, such as Figure 11 , 12As shown, the fuse can also be an elastic rubber ring 10 (melting point 140°C) made of the above-mentioned material. The connecting part of the second busbar 8 is in surface contact with the conductive connecting piece 2. The elastic rubber ring 10 is located outside the connection position between the connecting part of the second busbar 8 and the conductive connecting piece 2, thus securing the second busbar 8 and the conductive connecting piece 2 tightly.
[0048] In this embodiment, the elastic rubber ring 10 tightly connects the second busbar 8 and the conductive connecting piece 2. Since the melting point of the rubber ring is below 300°C, the high-temperature gas ejected when the explosion-proof valve is opened can melt the rubber ring. When the high-temperature gas ejected when the elastic rubber ring battery thermally runs away melts, the electrical connection between the second busbar and the conductive connecting piece 2 is broken, thereby disconnecting the monitoring circuit connected to the battery management system, causing circuit abnormality, realizing abnormal alarm, and achieving the purpose of early warning.
[0049] It should be noted that in the embodiments of the single-parallel structure battery module structure of this application, the elastic rubber ring 10 or the melting device of the hot melt rivet 9 can also be used in the embodiments of the single-parallel structure battery module structure of this application, and is not limited to use in the single-parallel structure battery module structure.
[0050] In the embodiments of the dual-parallel or single-parallel battery module structure of this application, the conductive connecting piece 2 can be a nickel sheet. Since nickel sheets are flexible, easy to process and have good conductivity, nickel sheets were chosen as conductive connecting pieces. Of course, other metal sheets with similar properties or nickel alloy sheets can also be selected, but are not limited to these.
[0051] In the embodiments of the dual-parallel or single-parallel battery module structure of this application, in order to ensure that the high-temperature gas ejected when the explosion-proof valve opens directly acts on the target position, namely the connection position between the first busbar / second busbar and the conductive connecting piece 2, and to effectively and quickly fuse the fuse device, in this embodiment of the application, the battery explosion-proof valve 5 is biased, that is, biased towards either the negative or positive electrode, and arranged close to the positive / negative electrode post of the battery cell for easy connection. A schematic diagram of the battery structure with the explosion-proof valve biased is shown below. Figure 5 As shown.
[0052] The shape of the explosion-proof valve 5 includes, but is not limited to, rectangular, circular, and other geometric shapes, and the size of the explosion-proof valve can be set according to the battery requirements.
[0053] This utility model embodiment also provides a battery module, including the battery module thermal runaway early warning device in the aforementioned embodiment of the dual parallel or single parallel structure battery module of this application. The device is melted by the high temperature gas ejected after the explosion-proof valve is opened in the early stage of thermal runaway, causing the busbar to disconnect from the conductive connecting piece 2, resulting in system circuit abnormality, thereby providing an immediate alarm for the occurrence of thermal runaway after the valve is opened.
[0054] In an exemplary embodiment of this application, another battery thermal runaway early warning device is also provided, such as... Figure 13 As shown, in the thermal runaway early warning device of this embodiment, a second flexible circuit board 13 is used. The provided second flexible circuit board 13 has an extended ribbon cable 15. The second flexible circuit board is connected to the second conductive connecting piece 12 connected to the third busbar 11 through the extended ribbon cable 15. The extended ribbon cable 15 is placed above the battery explosion-proof valve 5. In this embodiment, the cell explosion-proof valve 5 can be biased and arranged close to the positive / negative terminal of the cell. The structure of its single cell is shown in [reference]. Figure 5 As shown.
[0055] In this embodiment, the difference between the second flexible circuit board 13 and the first flexible circuit board 3 is that a separate protruding ribbon cable 15 is arranged or connected to it, and the protruding ribbon cable is used as a fuse to form a fuse structure.
[0056] In this embodiment, when the battery's explosion-proof valve 5 opens and explodes, it causes a short circuit between the third busbar 11 and the battery casing, melting the extended cable 15 of the third flexible circuit board (FPC), thus achieving a warning of thermal runaway. Figure 13 As shown.
[0057] In this application, the second busbar has the same function and role as the first and second busbars, only the shape is different, and its specific shape is set to different shapes according to the needs of the connected battery.
[0058] like Figure 13 As shown in the embodiment of this application, the third busbar and the second conductive connecting piece 12 are laser welded, not tin welded. In this embodiment, the structure of the second flexible circuit board (FPC) is changed so that the protruding ribbon cable connected to the second flexible circuit board (FPC) passes directly above the explosion-proof valve and is connected to the third busbar 11 through the second conductive connecting piece 12; wherein, the protruding ribbon cable 15 of the second flexible circuit board (FPC) 13 is bonded to the exposed metal part of the battery top cover around the corresponding explosion-proof valve 5.
[0059] Under some implementations, such as Figure 13 As shown, the structure of the battery top cover insulation sheet can be changed, and the opening 14 of the top cover insulation sheet around the battery explosion-proof valve can be enlarged, so that the metal of the top cover around the explosion-proof valve 5 is exposed, so as to facilitate bonding with the protruding cable 15.
[0060] like Figure 13 As shown, in this embodiment, the protruding ribbon cable 15 can be a low-melting-point ribbon cable, such as an aluminum ribbon cable (melting point around 660°C), and the non-metallic coating outside the protruding ribbon cable can be a low-melting-point non-metallic material, such as PET (melting point 250°C) or other low-melting-point non-metallic materials with a melting point not higher than 300°C.
[0061] like Figure 13 As shown in this embodiment, when the explosion-proof valve opens, the ejected high-temperature gas rapidly melts the non-metallic material (such as PET material with a low melting point) covering the protruding wires of the second flexible circuit board (FPC), exposing the aluminum wires (melting point of about 660°C) of the second flexible circuit board (FPC) above the explosion-proof valve. At this time, the battery casing of the thermal runaway valve opening has a positive potential, and the second flexible circuit board (FPC) is connected to the third bus at the negative terminal position. Due to the potential difference between the third bus and the battery casing, after the exposed aluminum wires come into contact with the exposed metal part of the battery top cover, the battery casing and the third bus form a short circuit, causing the aluminum wires (which melt faster) to heat up and melt rapidly. After the aluminum wires melt, the system monitoring circuit is abnormal, and a thermal runaway warning can be issued.
[0062] The warning device using the extended cable type 15 in this embodiment is also applicable to single or multiple batteries in parallel, simply by changing the length of the second flexible circuit board above the explosion-proof valve.
[0063] In the embodiment of the fuse device for the second flexible circuit board with protruding ribbon cable of this application, the second conductive connecting piece 12 can also be a nickel sheet. Since nickel sheets are flexible, easy to process and have good conductivity, nickel sheets were chosen as conductive connecting pieces. Of course, other metal sheets with similar properties or nickel alloy sheets can also be selected, and it is not limited to these.
[0064] This utility model embodiment also provides a battery module, including the battery module thermal runaway early warning device. The provided second flexible circuit board has an extended ribbon cable. The second flexible circuit board is connected to the second conductive connecting piece 12 connected to the third busbar through the extended ribbon cable. The extended ribbon cable is placed above the battery explosion-proof valve. When the battery explosion-proof valve opens and explodes, it will cause a short circuit between the third busbar and the battery casing, melting the extended ribbon cable of the second flexible circuit board (FPC), thereby realizing the early warning of thermal runaway.
[0065] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. It is obvious to those skilled in the art that this utility model is not limited to the details of the above exemplary embodiments, and that it can be implemented in other specific forms without departing from the spirit or basic features of this utility model.
[0066] Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects, and the scope of the present invention is defined by the appended claims rather than the foregoing description. Thus, it is intended to encompass all variations falling within the meaning and scope of the equivalents of the claims within the present invention.
[0067] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.
Claims
1. A battery module thermal runaway early warning device, comprising a flexible circuit board of the battery module and a busbar connecting the battery cells; characterized in that, The flexible circuit board is connected to a conductive connecting piece, which is connected to the busbar via a fuse. The fuse can be melted by the high-temperature gas emitted when the explosion-proof valve is opened during battery thermal runaway, thereby disconnecting the conductive connecting piece from the busbar.
2. The battery module thermal runaway early warning device according to claim 1, characterized in that, The fuse is located above the explosion-proof valves of two adjacent batteries on the large surface / above the explosion-proof valve of the battery cell.
3. The battery module thermal runaway early warning device according to claim 2, characterized in that, The fuse includes a solder layer formed of tin, lead-tin alloy or bismuth-tin alloy, and the bus connection portion is soldered to the conductive connecting piece through the solder layer, the conductive connecting piece being located below the bus.
4. The battery module thermal runaway early warning device according to claim 2, characterized in that, The fusion device includes a connector made of an elastic / inelastic polymer material.
5. The battery module thermal runaway early warning device according to claim 4, characterized in that, The fusion device includes a thermoplastic rivet, the connecting part of the busbar is in contact with the conductive connecting piece, and the thermoplastic rivet passes through the connecting part of the busbar and the conductive connecting piece to connect the busbar and the conductive connecting piece.
6. The battery module thermal runaway early warning device according to claim 4, characterized in that, The fusion device includes an elastic rubber ring. The connecting part of the busbar is in contact with the conductive connecting piece. The elastic rubber ring is sleeved on the outside of the connection position between the connecting part of the busbar and the conductive connecting piece, thereby securing the busbar and the conductive connecting piece tightly.
7. The battery module thermal runaway early warning device according to claim 1, characterized in that, The cell explosion-proof valve is biased and arranged close to the positive / negative terminal of the cell.
8. A battery module thermal runaway early warning device, comprising a flexible circuit board of the battery module and a busbar connecting the battery cells; characterized in that, The flexible circuit board has an extended ribbon cable connected to a conductive connecting piece, which is electrically connected to the busbar. The extended ribbon cable is located above the cell explosion-proof valve. The extended ribbon cable includes a metal wire and a non-metallic film covering the metal wire. The non-metallic film can be melted by the high-temperature gas emitted by the explosion-proof valve when the battery thermal runaway is activated, exposing the metal wire and making contact with the exposed metal of the battery top cover. This creates a short circuit between the battery casing and the busbar, melting the metal wire and breaking the electrical connection between the flexible circuit board and the busbar.
9. The battery module thermal runaway early warning device according to claim 8, characterized in that, The metal wire is made of aluminum, and the cell explosion-proof valve is biased and arranged close to the positive / negative terminal of the cell.
10. A battery module, characterized in that, Includes the battery module thermal runaway early warning device according to any one of claims 1-9.