Battery Module Connector Sealing Structure for Flame Containment
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Solution Overview
Problem
Conventional battery modules face issues with thermal propagation during thermal events, leading to potential ignition or explosion, as flames can spread between adjacent modules due to exposed connectors, compromising safety and structural stability.
Innovation Solution
A battery module design featuring a connector with a heat-resistant cover and heat blocking member, along with a sealing portion, to minimize flame discharge and prevent simultaneous ignition between modules, using materials like liquid crystal polymer, ceramic, and graphite for enhanced heat resistance and flame blocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are exposed for electrical connection, then electrical connectivity is achieved, but flame exposure and thermal propagation occur
Solution Approach 1:
A cover structure is introduced as an intermediary element between the connector and the external environment. The cover includes a blocking portion that specifically blocks flame while allowing electrical connection, and a sealing portion that seals the gap between the cover and module case to prevent flame leakage. This intermediary structure resolves the contradiction by maintaining electrical connectivity while blocking harmful flame exposure.
2Reliability
If thermal propagation is not suppressed, then thermal events can occur in adjacent modules, but this leads to ignition or explosion
Solution Approach 1:
The sealing portion is designed to seal the gap between the cover and module case, converting the potential harm of flame leakage into a beneficial containment effect. By sealing the gap, the system prevents flame from escaping through the connector region, thereby suppressing thermal propagation to adjacent modules and eliminating ignition or explosion risks.
3Object-affected harmful factors
If a cover with blocking portion is added, then flame blocking is improved, but device complexity increases
Solution Approach 1:
The cover structure merges multiple functions into a single integrated component. The blocking portion and sealing portion are combined in one cover structure that is coupled to the module case. This merging approach improves flame blocking capability while minimizing the increase in device complexity by consolidating protective functions rather than adding separate components.
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 solution effectively suppresses flame transition and minimizes the risk of simultaneous ignition between battery modules, enhancing structural stability and safety by containing flames within the module case and preventing external exposure.
Implementation Method 1
a heat blocking member provided on a side of the second portion facing the cell assembly
Implementation Method 2
a sealing portion configured to seal a gap between the first portion and the module case
Data Source
AI summary
A battery module includes a cell assembly; a module case for accommodating the cell assembly therein; and a connector provided in the module case and having a cover configured to block flame discharged from the cell assembly.