Battery Module Busbar Spacing During Thermal Runaway
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Solution Overview
Problem
In battery modules and packs, thermal runaway can lead to electrical shorts between busbars due to the collapse of the busbar frame, causing safety risks such as chain ignition or explosion, as existing heat insulating members do not effectively prevent electrical shorts.
Innovation Solution
Incorporating short-circuit prevention members with a melting point higher than the busbar frame, made of materials like mica, ceramic wool, or aerogel, to maintain a safe distance between busbars during thermal runaway, either by being inserted into the busbar assembly or disposed between adjacent busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar frame is used to support busbars and maintain safety distance, then the busbars are structurally supported and safety distance is maintained under normal conditions, but the busbar frame collapses when exposed to high-temperature gas or flame during thermal runaway, causing electrical shorts
Solution Approach 1:
A heat-resistant insulating member is introduced as an intermediary component between the busbars and the busbar frame. This insulating member has a melting point higher than the busbar frame material, serving as a mediator that maintains the safety distance and electrical isolation even when the busbar frame collapses under thermal runaway conditions. The insulating member transfers the mechanical support function from the heat-vulnerable busbar frame to a heat-resistant component.
Solution Approach 2:
The busbar assembly employs a composite structure combining the busbar frame (made of heat-vulnerable material like plastic) with a heat-resistant insulating member (made of high-melting-point material). This composite approach allows the system to benefit from both the ease of manufacturing the frame and the thermal stability of the insulating member, resolving the contradiction between structural support and heat resistance.
2Object-affected harmful factors
If heat insulating members are placed between battery cells to delay heat transfer, then heat transfer between cells is delayed during thermal runaway, but electrical shorts between busbars still occur due to frame collapse
Solution Approach 1:
The solution applies local quality by placing heat-resistant insulating members specifically at critical locations where electrical isolation is needed - between adjacent busbars and between busbars and battery cells. Rather than uniformly insulating all components, the insulating members are strategically positioned to address the specific electrical isolation vulnerability caused by frame collapse, while heat insulating members between cells continue to provide thermal protection.
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 electrical shorts and maintains structural integrity by keeping busbars isolated, even under high-temperature conditions, thereby reducing the risk of chain ignition and ensuring electrical stability.
Implementation Method 1
one or more short-circuit prevention members disposed on at least part of the insulation cover to electrically isolate the plurality of electrically conductive connectors from each other
Data Source
AI summary
A battery module and a battery pack are provided, a battery module including a cell stack including a plurality of battery cells; a housing including an internal space to accommodate the cell stack; a plurality of electrically conductive connectors electrically connected to the plurality of battery cells, a support frame arranged to face at least one side surface of the cell stack and supporting the plurality of electrically conductive connectors; an insulation cover disposed between the support frame and the housing; and one or more short-circuit prevention members disposed on at least part of the insulation cover to electrically isolate the plurality of electrically conductive connectors from each other.