Battery Module Guard Assembly for Nail Penetration Arc Suppression
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Solution Overview
Problem
Battery modules connected in series are prone to severe arcing, fire, and combustion during nail penetration tests, which poses a safety risk.
Innovation Solution
A battery module design that includes multiple battery cores connected in series, a guard assembly with stacked metal and insulation members, and a protection component like a fuse, which forms loops and short-circuit paths to prevent arcing and combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If multiple battery cores are connected in series to increase voltage and capacity, then the energy storage performance is improved, but the risk of arcing, fire, and combustion during nail penetration tests increases
Solution Approach 1:
An insulation component is introduced as an intermediary element between battery cores connected in series. This insulation component prevents direct electrical contact between adjacent battery cores, thereby blocking the formation of harmful arcing paths while maintaining the series connection for energy storage enhancement.
Solution Approach 2:
The harmful arcing path is extracted or removed from the system by introducing insulation barriers that prevent direct contact between battery cores. This extraction of the dangerous conductive path allows the series connection to maintain its energy storage function without the associated fire and combustion risks.
2Productivity
If battery cores are arranged in series connection to improve energy density, then the productivity and capacity are enhanced, but the safety performance during nail penetration tests deteriorates
Solution Approach 1:
Insulation components serve as mediator elements positioned between battery cores in series connection. These intermediaries maintain the electrical isolation necessary for safety while allowing the series architecture to achieve high energy density and capacity, thus resolving the conflict between productivity and reliability.
Solution Approach 2:
The battery module is segmented into distinct electrical zones using insulation components. This segmentation creates separate electrical domains between battery cores, preventing the propagation of arcing and fire while maintaining the series connection for enhanced energy density and productivity.
3Reliability
If insulation components are added between battery cores to prevent arcing, then the safety performance is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Thin film insulation materials are used to provide effective electrical isolation between battery cores without adding significant structural complexity. These thin film solutions maintain safety performance while minimizing the increase in device complexity and manufacturing difficulty.
Solution Approach 2:
Composite material structures combining insulation and structural functions are employed to prevent arcing between battery cores. These composite solutions integrate safety features into the existing module architecture, improving safety performance without proportionally increasing device complexity or manufacturing complexity.
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 design effectively prevents arcing, fire, and combustion during nail penetration tests by forming loops and short-circuit paths that quickly cut off the circuit, thereby enhancing the safety performance of the battery module.
Implementation Method 1
When the test steel nail penetrates the battery core corresponding to the second metal member in the second battery core group, a short-circuit loop is added to the battery module
Implementation Method 2
a loop is formed in the battery module. When the test steel nail penetrates the battery core corresponding to the second metal member in the second battery core group, a short-circuit loop is added to the battery module
Data Source
AI summary
A battery module, a nail penetration protection method for a battery module, and a vehicle are disclosed. The battery module comprises: multiple battery cores connected in series and comprising a first battery core group and a second battery core group, each including at least one battery core; a guard assembly comprising a first metal member, a first insulating member, and a second metal member; and a protection component being capable of cutting off a circuit. When a test steel nail sequentially penetrates through the battery core corresponding to the first metal member in the first battery core group, the first metal member, the first insulating member, and the second metal member, the battery module forms a loop; and when the test steel nail penetrates the battery core corresponding to the second metal member in the second battery core group, a short circuit loop is added in the battery module.