Battery Module Bus Bar Safety Member for External Short Interruption
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Solution Overview
Problem
Existing battery modules lack effective safety measures against external short circuits, which can lead to explosions or ignitions, and conventional solutions like bus bars with notched structures or external fuses compromise spatial efficiency and safety.
Innovation Solution
A battery module design featuring a safety member with a conductive layer and insulating layers made of materials that melt or vaporize with temperature rise, inducing a forced internal short circuit when an external short occurs, thereby interrupting current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bus bar with notched structure is used to interrupt current during external short circuit, then current interruption is achieved at specific resistance, but the interruption fails outside specific resistance range and spatial efficiency is reduced
Solution Approach 1:
The patent changes the physical state parameter of the insulating layer from solid to liquid/gas through temperature-induced phase transition. When external short circuit occurs and temperature rises, the insulating layer melts or vaporizes, transforming its electrical properties from insulating to conductive, thereby enabling current interruption across various resistance values without being limited to a specific resistance range.
Solution Approach 2:
The patent converts the harmful effect of temperature rise during external short circuit into a beneficial safety mechanism. The temperature increase, which would normally indicate a dangerous condition, triggers the insulating layer to melt or vaporize, creating a conductive path that intentionally induces an internal short circuit to interrupt the external short circuit current, thereby transforming thermal harm into protective action.
2Reliability
If an additional fuse is disposed outside the battery module to interrupt current, then current interruption is achieved, but spatial efficiency and utilization of the battery pack are deteriorated
Solution Approach 1:
The patent merges the safety protection function with the existing bus bar structure by integrating the insulating layer directly onto the bus bar. This combination eliminates the need for separate external fuses or safety devices, as the bus bar itself becomes the current interruption mechanism through the temperature-responsive insulating layer, thereby maintaining current interruption capability while reducing overall battery pack volume.
Solution Approach 2:
The patent implements a self-service safety mechanism where the battery module's own structural components (bus bar with insulating layer) perform the current interruption function without requiring external safety devices. The insulating layer automatically responds to temperature changes and triggers current interruption internally, making the system self-protecting and eliminating the need for additional space-consuming external fuses.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed solution effectively interrupts current flow during external short circuits, enhancing the safety of the battery module and pack by preventing explosions or ignitions without the need for external safety members.
Implementation Method 1
the first insulating layer and the second insulating layer include a material that is electrically insulating and is removed in accordance with the rise of temperature
Implementation Method 2
the first insulating layer and the second insulating layer include a material that is electrically insulating and is removed in accordance with the rise of temperature
Implementation Method 3
a conductive layer located on the first insulating layer and the second insulating layer
Data Source
AI summary
The battery module includes: a battery cell stack in which a plurality of battery cells including electrode leads are stacked; a plurality of bus bars including a first bus bar and a second bus bar that are respectively connected to at least one of the electrode leads; and a safety member that comes into contact with each of the first bus bar and the second bus bar, wherein the safety member includes a first insulating layer located on the first bus bar, a second insulating layer located on the second bus bar, and a conductive layer located on the first insulating layer and the second insulating layer, and wherein the first insulating layer and the second insulating layer include a material that is electrically insulating and is removed in accordance with the rise of temperature.