Battery Module Connector Sealing Against Thermal Runaway Venting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery modules fail to prevent the spread of high-temperature and high-pressure environments caused by flames or venting gas during thermal runaway, which compromises safety and fails to meet thermal runaway test standards.
Innovation Solution
A battery module with a connector featuring a connector gasket and header body made of materials with a melting point of 1000°C or higher, ensuring airtightness and preventing the spread of high-temperature and high-pressure environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional plastic injection connector is used, then the connector is easy to manufacture and cost-effective, but it melts at high temperatures causing structural collapse and loss of airtightness during thermal runaway
Solution Approach 1:
The patent changes the material parameter of the connector from conventional plastic injection material to heat-resistant material with melting point of 1000°C or higher. This parameter change enables the connector to maintain structural integrity and airtightness during thermal runaway events while remaining manufacturable through established processes adapted for heat-resistant materials.
Solution Approach 2:
The patent employs composite material construction for the connector, combining heat-resistant materials (such as ceramic-coated metals or high-temperature polymers) with conventional connector components. This composite approach achieves both high-temperature resistance and manufacturability, allowing the connector to withstand thermal runaway conditions while maintaining ease of integration into existing battery module assemblies.
2Strength
If the connector is sealed by welding with module case, then connection strength is improved, but the plastic injection portions still melt at high temperatures compromising overall safety
Solution Approach 1:
The patent changes the thermal resistance parameter of the connector materials to withstand temperatures of 1000°C or higher. By selecting heat-resistant materials for both the connector body and sealing components, the system achieves both strong connections and resistance to high-temperature spread during thermal runaway, eliminating the vulnerability of plastic injection portions.
3Quantity of substance
If battery cells are densely packed in narrow space, then energy density is improved, but fire safety becomes more difficult to maintain during thermal runaway
Solution Approach 1:
The patent introduces heat-resistant connectors as intermediary components between densely packed battery cells. These connectors act as thermal barriers that can withstand high temperatures and prevent fire spread, allowing the battery module to maintain high cell density while improving fire safety through the protective intermediary material.
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 improved connector maintains airtightness and withstands high temperatures and pressures, preventing flame and gas diffusion, thus meeting safety standards and enhancing the safety of battery modules, packs, and vehicles.
Implementation Method 1
a connector gasket located between the module case and the connector header body and having a melting point of 1000°C or higher
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery module according to the present disclosure includes a cell assembly including at least one battery cell, a module case in which the cell assembly is accommodated, and a connector mounted on the module case. The connector includes a connector terminal for electrical connection with the battery cell, a connector housing surrounding the connector terminal, a connector header body coupled to the connector housing and mounted on the module case in such a manner that at least a part of the connector header body is inserted into the module case, and a connector gasket located between the module case and the connector header body and having a melting point of 1000°C or higher.