Battery Module Connector Housing With Flame-Retardant Gas Venting
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Solution Overview
Problem
Conventional battery modules are vulnerable to fire propagation due to the exposure of connectors made of plastic material, which melt and discharge high-temperature gas and flame, risking ignition of adjacent modules.
Innovation Solution
A battery module design featuring a flame retardant block made of aluminum with a ceramic coating, a sealing gasket, and a fixing plate, integrated with a metal main housing and venting holes, to contain and direct high-temperature gas through a pre-intended safety path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector is made of plastic material for ease of manufacture and cost reduction, then the manufacturing cost is reduced, but the flame retardancy is poor and the connector melts under high temperature
Solution Approach 1:
The connector is constructed as a composite structure with a plastic housing providing ease of manufacture and a metal flame retardant block providing thermal resistance. The metal block is embedded within the plastic housing, creating a composite connector that combines the advantages of both materials: the plastic portion is easy to manufacture via injection molding while the metal block provides the necessary flame retardancy and structural stability under high temperature conditions.
2Ease of operation
If the connector is exposed to the outside for ease of connection, then the connection is simplified, but the gas and flame are easily discharged to the outside through the connector
Solution Approach 1:
The metal flame retardant block acts as an intermediary barrier between the internal battery module and the external environment. It is positioned at the connection point where the connector exits the module, serving as a thermal firewall that prevents direct discharge of gas and flame to the outside while still allowing electrical connection to pass through. The block's high melting point and thermal stability enable it to withstand thermal runaway conditions and redirect exhaust through designated safety paths.
3Volume of moving object
If the connector is made thinner to reduce space occupation, then the space is saved, but the flame retardancy is reduced
Solution Approach 1:
The connector employs local quality enhancement by concentrating the flame retardant metal block only at the critical thermal exposure zones - specifically at the portion exposed to the outside and at the connection points. The metal block has a thickness of 3-10mm at these critical locations, providing maximum flame retardancy where needed. Other portions of the connector can be thinner, optimizing the balance between space occupation and flame retardancy by applying material thickness selectively where thermal protection is most required.
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 suppresses connector melting and minimizes fire propagation by enhancing flame retardancy, allowing controlled gas discharge and reducing thermal damage to neighboring modules.
Implementation Method 1
a coating layer which is coated on the lower surface of the flame retardant block, wherein the coating layer includes ceramic particles
Implementation Method 2
discharge the gas through a pre-intended safety path
Data Source
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AI summary
A battery module according to the present disclosure includes a cell assembly having battery cells; a module case accommodating the cell assembly and having a connector mounting hole at one side; and a connector assembly connected to a circuit board provided inside the module case and having at least a portion exposed to the outside of the module case through the connector mounting hole, wherein the connector assembly includes a connector housing having connector pins inside and having at least a portion exposed to the outside of the connector mounting hole; and a flame retardant block formed of a metal material and surrounding the circumference of the connector housing inside the module case, wherein the flame retardant block has a coating layer of an incombustible material on the surface facing the inside of the module case.