Protective Frame Busbar Layout for Battery Thermal Runaway
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Solution Overview
Problem
Battery packs face the challenge of protecting busbars and measurement wires from damage or short-circuiting due to high-temperature and high-pressure gas emitted during thermal runaway in battery modules, which can lead to explosions.
Innovation Solution
A battery pack design featuring a protective frame with slots and insertion holes that securely house busbars and measurement wires, preventing exposure to hazardous gases and providing compartmentalization to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars and measurement wires are installed across the battery pack through the space between battery modules, then electrical connection and measurement functions are achieved, but the components are exposed to high-temperature and high-pressure gas during thermal runaway, causing damage or short-circuiting
Solution Approach 1:
The battery pack is divided into multiple compartments using partition walls and protective frames. Each compartment contains specific battery modules, and the partition walls prevent high-temperature gas from one compartment from reaching busbars and measurement wires in other compartments. This segmentation isolates the harmful thermal runaway effects to specific areas while protecting critical electrical components.
Solution Approach 2:
Protective frames and partition walls are introduced as intermediary structures between the battery modules and the busbars/measurement wires. These intermediaries physically block the path of high-temperature gas, preventing direct contact with the electrical components. The protective frames serve as a mediator that absorbs or redirects the harmful gas flow away from vulnerable areas.
2Reliability
If a protective frame with slots and insertion holes is introduced to protect busbars and measurement wires, then damage and short-circuiting are prevented, but the device complexity increases
Solution Approach 1:
The protective frame is designed to serve multiple functions simultaneously: it provides structural support for the battery pack, creates compartmentalization to contain thermal runaway, provides pathways for busbars and measurement wires through slots and insertion holes, and acts as a barrier against high-temperature gas. By combining these functions into a single component, the overall device complexity is minimized while achieving comprehensive protection.
Solution Approach 2:
The protective frame utilizes a thin-walled structure with integrated slots and insertion holes that provides effective protection without adding significant bulk or complexity. The design allows busbars and measurement wires to pass through predefined openings while the thin protective barriers effectively block high-temperature gas, achieving protection with minimal structural complexity.
Data Source
AI summary
A battery pack includes a pack case that includes external terminals formed on one side and contains a plurality of battery modules inside; a protective frame that extends across the pack case and defines the module area; a busbar that electrically connects the battery modules and the external terminals of the pack case; and a battery management unit located on the other side opposite to the pack case from where the external terminals are formed. The protective frame includes slots extending along the length direction of the protective frame, the module area is compartmentalized by the protective frame and includes a first battery part formed on one side of the protective frame and a second battery part formed on the opposite side of the protective frame, the busbar is inserted and secured within the slots of the protective frame, and the protective frame surrounds its sides.