Battery Pack Barrier Sealing at Bus Bar Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery packs face challenges in effectively suppressing thermal propagation between modules, particularly at the bus bar connections, which can lead to failures, explosions, or fires.
Innovation Solution
A battery pack design incorporating a barrier unit with a bus bar unit that seals the electrical connection points between modules, using a bus bar unit with a conduction portion and a sealing portion to prevent thermal propagation, and optionally including a blocking portion for enhanced safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional barrier is provided between battery modules, then thermal propagation is partially suppressed, but thermal propagation cannot be completely blocked due to gaps at bus bar installation portions
Solution Approach 1:
The barrier is divided into a barrier body and a separate cover portion. The cover portion specifically seals the bus bar installation portions, while the barrier body provides general thermal isolation. This segmentation allows each component to address specific thermal propagation paths without requiring complete redesign of the entire barrier structure.
Solution Approach 2:
The cover portion is designed to fit over and seal the bus bar installation portions on the barrier body. This nested configuration ensures that the bus bar connections, which are potential thermal propagation pathways, are enclosed within the barrier structure, preventing flame and gas from passing through these critical areas.
2Ease of operation
If battery modules are electrically connected through bus bar installation portions, then electrical connectivity is achieved, but thermal propagation occurs since flame or gas flows through these portions
Solution Approach 1:
The cover portion acts as an intermediary element between the bus bar installation portions and the external environment. It provides a sealing interface that allows the bus bar to maintain electrical connectivity while preventing thermal propagation. The cover portion mediates between the need for electrical connection and the need for thermal isolation.
3Device complexity
If the barrier structure is simplified without a cover portion, then device complexity is reduced, but thermal propagation prevention at bus bar portions is compromised
Solution Approach 1:
The barrier system is segmented into functional components: the barrier body for general thermal isolation and the cover portion for sealing bus bar areas. This segmentation allows the structure to remain relatively simple while addressing specific thermal propagation risks at critical locations without requiring complete structural redesign.
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 the spread of gas or flame between battery modules, ensuring safer operation by sealing the connection points and reducing thermal propagation risks.
Implementation Method 1
a bus bar unit configured to electrically connect module terminals of different battery modules and located at an end or inside of the barrier unit to seal the end or inside of the barrier unit
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed is a battery pack with improved safety to more effectively prevent thermal propagation between battery modules. The battery pack includes a plurality of battery modules, each of which includes at least one battery cell and a module terminal; a barrier unit interposed between adjacent battery modules; and a bus bar unit configured to electrically connect module terminals of different battery modules and located at an end or inside of the barrier unit to seal the end or inside of the barrier unit.