Battery Pack Case Recess Insulation Against Electrolyte Shorting
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Solution Overview
Problem
Conventional battery pack cases for vehicles are prone to fire or thermal runaway due to electrical connections between the module chassis and the battery pack chassis, which occur when electrolyte leaks from damaged battery cells and accumulates in recessed parts of the vehicle body.
Innovation Solution
A battery pack case design that includes a lower panel supporting the battery pack, a recessed part with a groove shape extending from the upper surface of the lower panel, and an insulating sheet attached to the recessed part to prevent electrical connections between the module chassis and the battery pack chassis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a recessed part is formed in the lower panel to support the battery pack, then the battery pack can be securely positioned between cross members, but electrolyte can accumulate in the recessed part causing electrical connection between module chassis and battery pack chassis
Solution Approach 1:
An insulating sheet is introduced as an intermediary component between the lower panel and the battery pack. This insulating sheet prevents direct contact between the electrolyte (harmful substance) and the electrical connection path, thereby blocking the harmful effect while maintaining the structural support function of the recessed part.
Solution Approach 2:
A thin insulating sheet is applied to the recessed part of the lower panel. This thin film provides electrical insulation to prevent electrolyte-induced electrical connection while conforming to the recessed geometry and not interfering with the battery pack's secure positioning.
2Ease of manufacture
If the battery pack case structure is simplified without insulating components, then manufacturing is easier and cost is reduced, but fire or thermal runaway can occur due to electrical connection from electrolyte leaks
Solution Approach 1:
A thin insulating sheet, which is inexpensive and simple to apply, is used to prevent fire or thermal runaway. This low-cost component provides critical safety protection without adding significant manufacturing complexity or cost to the battery pack case.
Solution Approach 2:
The insulating sheet serves as a simple intermediary layer that can be easily integrated into the existing manufacturing process, providing fire prevention reliability without significantly complicating the manufacturing procedure.
3Reliability
If an insulating sheet is added to the recessed part to prevent electrical connection, then fire or thermal runaway is prevented, but device complexity increases
Solution Approach 1:
A thin insulating sheet is used instead of a complex insulating structure. This thin film provides the necessary fire prevention reliability while adding minimal structural complexity to the battery pack case design.
Solution Approach 2:
The insulating sheet is a simple, inexpensive component that can be easily applied to the recessed part, providing fire prevention reliability without significantly increasing device complexity.
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 design effectively prevents fire or thermal runaway by insulating the battery pack case, thereby preventing short circuits caused by electrolyte leaks, even in high-temperature situations.
Implementation Method 1
an insulating sheet attached to the recessed part to insulate between the lower panel and the battery pack
Data Source
AI summary
A battery pack case for a vehicle includes: a lower panel having a battery pack seated to support a lower surface of the battery pack; a recessed part formed on an upper surface of the lower panel and having a groove shape indented downward to extend; and an insulating sheet extending along the recessed part and attached to the recessed part to insulate between the lower panel and the battery pack at a point where the recessed part is formed.