Battery Connector Sealing Plate for Thermal Runaway Gas Retention
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Solution Overview
Problem
Existing battery connectors in electric vehicles are prone to gas leakage during thermal runaway events, posing a significant safety risk due to weakened areas that fail under high pressure and temperature, necessitating improved sealing mechanisms.
Innovation Solution
A battery connector design featuring a plate that covers the external connector's footprint while maintaining connection points, combined with a circuit board and internal wiring, enhances sealing and pressure retention, using materials like composite carbon fiber or fiberglass to withstand high temperatures and prevent gas escape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a battery connector is used to provide external connections, then electrical connectivity is enabled, but the connector creates a weakened area that leaks gases during thermal runaway
Solution Approach 1:
A plate is introduced as an intermediary component between the outer wall and the circuit board. This plate covers the hole through which the external connector passes, creating a sealing barrier that prevents gas leakage while allowing the connector to maintain its electrical function. The plate acts as a mediator that resolves the conflict between connectivity and sealing integrity.
Solution Approach 2:
The connector assembly is segmented into distinct functional components: the external connector for electrical connection, the circuit board for signal processing, and the plate for sealing. This segmentation allows each component to optimize its specific function without compromising the others, particularly enabling the plate to provide sealing independent of the connector's electrical function.
2Adaptability or versatility
If the outer wall is weakened to accommodate connectors, then external connections are possible, but the weakened areas fail under high pressure and temperature during thermal runaway
Solution Approach 1:
The plate is constructed from composite materials that combine thermal resistance, mechanical strength, and sealing properties. These composite materials enable the plate to withstand the high temperature and pressure conditions during thermal runaway while maintaining its sealing function, thus compensating for the weakened areas created by connector integration.
Solution Approach 2:
The plate is designed in advance to compensate for the structural weakening caused by the connector hole. By providing a reinforced sealing structure before thermal runaway occurs, the plate cushions against the high pressure and temperature stresses that will later be imposed during battery failure, preventing gas leakage through the weakened outer wall.
3Reliability
If a sealing plate is added to cover the connector hole, then gas leakage is prevented, but the construction complexity increases
Solution Approach 1:
The plate is designed to serve multiple functions simultaneously: it provides sealing to prevent gas leakage, structurally reinforces the outer wall around the connector hole, and can be integrated with the circuit board mounting structure. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in construction complexity while achieving improved sealing performance.
Data Source
AI summary
A battery case, connector, and method of forming are provided. The battery case includes, an outer wall, a plurality of first wires internal to the battery enclosure, and a battery connector. The battery connector includes an external connector, a circuit board connected to the external connector on a first side through a hole in the outer wall and connected to the plurality of first wires on a second side opposite the first side, where the circuit board is further bonded to an internal side of the outer wall on a portion of the first side, and a plate bonded to the second side of the circuit board opposite the first side, where the plate completely covers a footprint of the hole in the outer wall through which the external connector attaches to the circuit board, but does not cover connection points for the plurality of first wires.