Battery Pack Connector Structure for Thermal Runaway Containment
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Solution Overview
Problem
Conventional battery pack connectors made of low-heat-resistant materials melt during thermal runaway, allowing flames to spread and posing safety risks.
Innovation Solution
A connector design with a lower end portion made of a low-melting-point material and a main body portion made of a high-heat-resistant material, such as stainless steel or ceramic, prevents deformation and maintains the connector's shape even at high temperatures, inhibiting thermal runaway spread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plastic connectors are used in battery packs, then manufacturing cost is reduced and ease of manufacture is improved, but heat resistance is insufficient and thermal runaway prevention capability deteriorates
Solution Approach 1:
The connector is constructed as a composite structure combining a polyolefin resin base material with a flame retardant additive (such as aluminum hydroxide, magnesium hydroxide, or boron nitride). This composite approach maintains the ease of manufacturing injection-molded plastic components while achieving superior heat resistance and flame retardancy, with the flame retardant additive preventing thermal runaway at elevated temperatures.
Solution Approach 2:
The invention modifies the thermal properties of the connector material by incorporating flame retardant additives that raise the decomposition temperature and reduce flammability. The polyolefin resin is chemically or physically modified through the addition of heat-resistant compounds, transforming it from a thermoplastic that softens at low temperatures to a heat-resistant material capable of withstanding battery thermal runaway conditions.
2Temperature
If metal connectors are used in battery packs, then heat resistance and strength are improved, but manufacturing complexity increases and cost rises
Solution Approach 1:
The invention replaces expensive, difficult-to-manufacture metal connectors with a cost-effective plastic alternative that achieves comparable heat resistance through flame retardant additives. The polyolefin-based connector with incorporated flame retardants provides sufficient thermal stability to prevent thermal runaway, eliminating the need for metal construction while reducing manufacturing complexity and cost.
3Ease of manufacture
If conventional plastic connectors are used, then manufacturing cost is reduced, but reliability under high temperature conditions deteriorates
Solution Approach 1:
The connector uses a composite formulation of polyolefin resin combined with flame retardant additives (aluminum hydroxide, magnesium hydroxide, or boron nitride) to achieve both cost-effectiveness and high-temperature reliability. This composite material maintains dimensional stability and electrical insulation properties under thermal stress, preventing connector failure and battery thermal runaway while keeping manufacturing costs low through injection molding.
4Device complexity
If the connector structure is simplified, then manufacturing is easier, but thermal insulation capability and thermal runaway prevention deteriorate
Solution Approach 1:
The invention changes the thermal parameters of the connector material by incorporating flame retardant additives into the polyolefin resin. This modification enables a simple, unitary injection-molded structure to achieve superior thermal insulation and heat resistance, preventing thermal runaway without requiring complex multi-component or layered constructions.
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
Prevents melting and maintains the connector's integrity, thereby preventing flames from erupting and inhibiting thermal runaway spread, enhancing safety in battery packs.
Implementation Method 1
the connector has excellent heat resistance, thereby preventing thermal runaway
Implementation Method 2
the connector is made of a polyolefin resin base material with flame retardant
Data Source
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AI summary
The present invention relates to a connector for battery packs, the connector including a housing to which a terminal pin configured to serve as an electrical connection path is mounted, wherein the housing includes a lower end portion to which the terminal pin is coupled and a main body portion having a partition wall portion configured to prevent deformation of the terminal pin when an external terminal is coupled to the terminal pin, the lower end portion being mounted to the main body portion, and the lower end portion and the main body portion are made of different materials. Melting of the connector for battery packs is prevented, whereby spread of a thermal runaway phenomenon occurring in a battery pack to the outside is prevented.