Battery Pack Power Connector Assembly With Fire-Resistant Insulation
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Solution Overview
Problem
Medium- and large-format rechargeable batteries, particularly lithium-ion batteries, face challenges in preventing overheating and fire hazards, which can lead to safety risks and damage, especially in applications like vehicles where timely evacuation is critical.
Innovation Solution
The battery pack design incorporates a mixed material of resin and glass fiber in the enclosure case, along with mica tubes and plates for thermal insulation, and a thermistor temperature sensor holder to secure temperature sensors effectively, enhancing fire resistance and preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lithium-ion batteries are used to provide more electrical energy with less space, then energy density is improved, but the risk of overheating and fire hazards increases
Solution Approach 1:
The patent introduces an enclosure case made of fire-resistant materials (resin and glass fiber mixture) as an intermediary barrier between the battery cells and the external environment. This mediator prevents fire from spreading to other components and provides thermal insulation to protect against overheating, thereby reducing fire hazards while maintaining high energy density lithium-ion batteries
Solution Approach 2:
The patent uses a composite material consisting of resin and glass fiber in specific proportions (30-70% resin and 70-30% glass fiber) to create the enclosure case. This composite material combines the fire resistance and structural strength of glass fiber with the binding and insulation properties of resin, achieving both safety and performance requirements for high-energy-density battery packs
2Quantity of substance
If new battery technologies with higher energy density are implemented, then electrical energy storage is improved, but thermal management and fire safety become more difficult
Solution Approach 1:
The patent modifies the material composition parameters of the enclosure case by using a specific ratio of resin to glass fiber (30-70% and 70-30% respectively). This parameter change optimizes the thermal properties of the enclosure, providing better thermal insulation and fire resistance to manage the heat generated by high-capacity battery cells
Solution Approach 2:
The enclosure case acts as a thermal mediator between the battery cells and the external environment, using fire-resistant materials to control heat transfer. This intermediary structure prevents thermal runaway from spreading and maintains temperature control in battery packs with higher energy storage capacity
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 solution effectively prevents battery packs from catching fire and provides sufficient time for evacuation by reducing thermal heat transfer and incorporating advanced materials for insulation and temperature monitoring, thereby meeting industry fire resistance standards.
Implementation Method 1
The outer enclosure may include a filling material of both a resin and a glass fiber
Implementation Method 2
along with mica tubes and plates for thermal insulation
Data Source
AI summary
A medium- and/or large-format (M/L), rechargeable battery pack used for powering attached equipment may include features to protect the battery pack from external fire. For example, the features may protect the battery pack due to exposure to fire from outside of the end device, e.g., a vehicle, due to a fuel spill. According to another aspect of the embodiments, the M/L rechargeable battery pack may include a high current terminal/power connector for the battery pack. The embodiment optimizes the battery pack output power connector assembly, improves and solves poor connection designs that can cause fire hazards from sparks, and provides water ingress protection.