Battery Pack Power Connector Assembly for Fire and Water Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Medium- and large-format rechargeable batteries, particularly Li-ion batteries, face challenges in preventing overheating and fire hazards, which can lead to safety risks and damage, especially in applications like vehicles where timely evacuation is critical.
Innovation Solution
The battery pack design incorporates a mixed material of resin and glass fiber in the enclosure case, along with mica tubes and plates for thermal insulation, and a thermistor temperature sensor holder to secure thermistors effectively, enhancing fire resistance and temperature monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If Li-ion batteries are used to provide more electrical energy with less space, then energy density is improved, but fire hazard and overheating risk increase
Solution Approach 1:
The patent implements fire-resistant materials (resin and glass fiber mixture) and thermal insulation components (mica tubes and plates) as preventive measures before overheating or fire can occur. These cushioning elements are integrated into the battery pack structure to absorb and resist thermal damage, providing a safety buffer that prevents fire hazards while maintaining high energy density Li-ion batteries.
Solution Approach 2:
The patent uses a composite material of resin and glass fiber in the enclosure case, combined with mica thermal insulation components. This composite material approach provides both structural integrity and fire resistance, allowing the battery pack to maintain high energy density while protecting against the fire hazards inherent in Li-ion battery technology.
2Reliability
If fire-resistant materials and thermal insulation components are added to prevent overheating and fire, then safety is improved, but device complexity increases
Solution Approach 1:
The patent merges the fire-resistant enclosure case (made of resin and glass fiber composite) with thermal insulation functions by integrating mica tubes and plates into the existing battery pack structure. Rather than adding separate complex fire suppression systems, the design combines multiple safety functions into unified structural elements, thereby improving fire resistance while minimizing increases in device complexity.
Solution Approach 2:
The patent applies thermal insulation components (mica tubes and plates) at specific critical locations within the battery pack where heat generation and fire risk are highest. This localized approach provides targeted fire resistance and thermal protection without requiring complex fire-safe materials throughout the entire structure, thus improving safety while controlling structural 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 battery packs from catching fire and provides sufficient time for evacuation, meeting industry fire resistance standards, while ensuring reliable operation and safety in high-risk environments.
Implementation Method 1
The battery pack design incorporates a mixed material of resin and glass fiber in the enclosure case, along with mica tubes and plates for thermal insulation, and a thermistor temperature sensor holder to secure thermistors effectively, enhancing fire resistance and temperature monitoring.
Implementation Method 2
The battery pack design incorporates a mixed material of resin and glass fiber in the enclosure case, along with mica tubes and plates for thermal insulation
Implementation Method 3
a thermistor temperature sensor holder to secure thermistors effectively, enhancing fire resistance and temperature monitoring
Data Source
AI summary
A medium- and/or large-format (M/L), rechargeable battery pack used for powering attached equipment may include features to protect the battery pack from external fire. For example, the features may protect the battery pack due to exposure to fire from outside of the end device, e.g., a vehicle, due to a fuel spill. According to another aspect of the embodiments, the M/L rechargeable battery pack may include a high current terminal/power connector for the battery pack. The embodiment optimizes the battery pack output power connector assembly, improves and solves poor connection designs that can cause fire hazards from sparks, and provides water ingress protection.