Battery Module Connector Isolation for Internal Ignition Containment
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Solution Overview
Problem
Conventional battery modules are vulnerable to fire due to thermal propagation, as connectors made of injection-molded plastic materials melt and allow gas and flame to escape, potentially igniting adjacent modules.
Innovation Solution
A battery module design featuring a flame retardant cover made of fire-resistant and insulating material surrounding the connector mounting hole, with a connector housing isolated from the module case, and pins extending through the cover to prevent gas and flame emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a connector made of injection-molded plastic material is used for connection, then ease of manufacture is improved, but vulnerability to heat and flame increases, causing the connector to melt and emit gas and flame
Solution Approach 1:
A metal connector housing is introduced as an intermediary component between the plastic connector body and the fire hazard. The metal housing encloses the plastic connector, providing fire resistance and structural stability while the plastic connector maintains its ease of manufacture and electrical connection function.
2Ease of operation
If the connector is exposed to the outside for connection, then ease of operation is improved, but the risk of gas and flame emission to adjacent modules increases
Solution Approach 1:
The plastic connector is nested within the metal connector housing, creating a protective enclosure. This nested structure allows the connector to remain accessible for connection while the metal housing acts as a containment barrier that prevents fire and gas from reaching adjacent modules.
3Ease of manufacture
If assembly gaps are present in the module case for connector location, then ease of assembly is improved, but fire and gas can easily escape through these gaps
Solution Approach 1:
The metal connector housing provides localized fire resistance at the connector location, creating a fire-resistant zone around the plastic connector. This local quality enhancement ensures that even if assembly gaps exist in the module case, the fire and gas cannot escape through these gaps because the metal housing contains them.
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 suppresses the emission of gas and flame from the battery module, reducing the risk of fire spread and thermal damage to adjacent modules.
Implementation Method 1
a flame retardant cover made of fire-resistant and insulating material, provided to shield the connector mounting hole
Data Source
AI summary
A battery module may include battery cells; a module case accommodating the battery cells and having a connector mounting hole on one side; a flame retardant cover made of fire-resistant and insulating material, provided to shield the connector mounting hole; and a connector having a connector housing exposed to the outside through the connector mounting hole and isolated from the inside of the module case by the flame retardant cover, and connector pins extending into the module case through the flame retardant cover.