Battery Conductive Insulation to Prevent Thermal Runaway Ignition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional batteries are prone to high-voltage ignition during thermal runaway, leading to failure due to conductive components overlapping and forming connections in series, which reduces safety performance and service life.
Innovation Solution
The battery design incorporates conductive components such as bus, signal transmission, and power output components partially wrapped with an insulating medium having a melting point between 200°C and 1300°C, preventing conductive medium overlap and ensuring electrical isolation, thereby avoiding high-voltage ignition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery conductive components are left unwrapped, then manufacturing cost is reduced and structure is simplified, but during thermal runaway conductive components overlap and form series connections causing high-voltage ignition
Solution Approach 1:
An insulating medium is introduced as an intermediary substance between conductive components (bus bars, terminals, connectors) to prevent direct contact and electrical connection during thermal runaway events. This mediator maintains electrical isolation even when components deform or shift, thereby preventing high-voltage ignition without fundamentally redesigning the conductive component structure
Solution Approach 2:
The insulating medium is pre-applied to conductive components before assembly, creating a protective barrier in advance. This preliminary protective action ensures that when thermal runaway occurs and components may overlap, the electrical connection is already prevented by the pre-established insulating layer, avoiding high-voltage ignition
2Reliability
If insulating medium is applied to all conductive components, then electrical isolation is improved and high-voltage ignition is prevented, but manufacturing cost and production complexity increase
Solution Approach 1:
The insulating medium is selectively applied only to critical conductive components that are most likely to cause high-voltage ignition if they contact during thermal runaway (such as high-voltage bus bars and terminals), rather than uniformly coating all conductive elements. This localized approach maintains essential electrical isolation while reducing material consumption and manufacturing complexity
3Temperature
If insulating medium with high melting point is used, then resistance to thermal runaway conditions is improved, but material selection is restricted and cost increases
Solution Approach 1:
The insulating medium employs a composite material system combining inorganic fillers (such as aluminum oxide, magnesium oxide, or silicon oxide particles) with organic binder resins. This composite structure provides high-temperature resistance through the inorganic components while maintaining processability and adaptability through the organic matrix, allowing broader material selection and manufacturing flexibility
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
This design enhances safety performance and service life by preventing conductive component overlap and ensuring reliable electrical isolation, even during thermal runaway, while maintaining high energy density and reducing production costs.
Implementation Method 1
the external part of at least one of the bus component, the signal transmission component, and the power output component is at least partially wrapped with an insulating medium having a melting point in a range of greater than 200° C. and less than or equal to 1,300° C.
Implementation Method 2
The insulating medium with a melting point in this range will not melt during thermal runaway
Data Source
AI summary
The present application relates to a battery and a power consuming device, the battery comprising: a box body internally having an accommodating cavity; a battery pack arranged in the accommodating cavity; and a conductive component arranged in the accommodating cavity and comprising at least one of a bus component, a signal transmission component, and a power output component of the battery pack, wherein the external part of at least one of the bus component, the signal transmission component, and the power output component is at least partially wrapped with an insulating medium.