Battery Pack Bus Bar Fireproof Cover for Thermal Event Protection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Lithium secondary batteries are prone to overcharging and overheating, which can cause bus bar distortion leading to short circuits and damage due to thermal events, necessitating a solution to prevent such abnormal phenomena.

Innovation Solution

A battery pack design incorporating a fireproof cover that covers bus bars to prevent distortion during thermal events, using a pack case with a lower, side, inner, and upper frame, and a barrier frame, with a fireproof cover attached to the inner frame and barrier frame, and optionally a blocking cover made of mica.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bus bars are exposed in the battery pack, then electrical connection is achieved, but thermal events cause bus bar distortion leading to short circuits and damage

Engineering Contradiction:

Improvebus bar stabilityVSAvoidthermal event damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A fireproof cover made of heat-resistant material is introduced as an intermediary component between the bus bar and the thermal environment. The cover physically shields the bus bar from direct thermal exposure, preventing distortion and short circuits while maintaining electrical connectivity. This mediator approach resolves the contradiction by protecting the vulnerable bus bar without altering its electrical function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The fireproof cover is installed in advance on the battery pack structure, creating a protective barrier before thermal events occur. This pre-positioned protection cushioning ensures that when thermal events happen, the bus bar is already shielded, preventing distortion and electrical failures before they can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Object-affected harmful factors

If a fireproof cover is added to protect bus bars, then thermal protection is improved, but device complexity increases

Engineering Contradiction:

Improvethermal event resistanceVSAvoidbattery pack structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The fireproof cover is designed to serve multiple functions simultaneously: it protects bus bars from thermal events, maintains structural integrity of the battery pack, and can be integrated with existing frame structures. By making the cover multi-functional, the design adds protection without proportionally increasing complexity, as the same component performs several protective and structural roles.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The fireproof cover is designed to nest within or integrate with the existing battery pack frame structure, rather than adding completely separate external components. This nesting approach allows the protective cover to be incorporated into the existing structural framework, minimizing additional complexity while maximizing protection.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentEP4661203A1Battery pack and vehicle including same

Publication Date: 2025.12.10 LG ENERGY SOLUTION LTD

Figure 1
Figure 2~3
Figure 4

AI summary

Disclosed is a battery pack, and a vehicle including the same. The battery pack includes a plurality of battery modules in each of which a plurality of battery cells are stacked; a pack case in which the plurality of battery modules are accommodated; and a fireproof cover configured to cover a plurality of bus bars, which electrically connect the plurality of battery modules, to prevent an abnormal phenomenon of the bus bars when a thermal event occurs.