Battery Pack Cover Plate Assembly for Flame Propagation Control
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Solution Overview
Problem
Existing battery packs lack effective protection against the propagation of sparks or flames to adjacent battery units, particularly on upper and front surfaces, which are vulnerable to ignition and electrical short-circuits.
Innovation Solution
The battery pack incorporates cover plate assemblies that cover both the upper and front surfaces of battery units, preventing the spread of sparks or flames to adjacent units. Each cover plate assembly includes an upper cover plate and a front cover plate, with fastening parts that secure to partition members, ensuring comprehensive protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery modules are arranged closely to increase power density, then productivity and space utilization are improved, but the risk of flame propagation to adjacent units increases
Solution Approach 1:
The patent introduces partition members that divide the battery pack into multiple independent compartments, each containing individual battery modules. This segmentation prevents flame propagation between adjacent modules while maintaining close arrangement for high power density. The partition members create physical barriers that isolate thermal runaway events to specific compartments.
Solution Approach 2:
The patent employs cover plate assemblies as intermediary protective elements positioned between battery modules. These cover plates serve as mediators that block direct flame and spark transmission while allowing the modules to remain in close proximity. The intermediary structure enables safe high-density arrangement by actively intervening in the flame propagation path.
2Ease of operation
If the front surface of battery modules is left exposed for terminal access, then ease of operation is improved, but electrical short-circuit and ignition vulnerability increase
Solution Approach 1:
The patent applies different protective qualities to different regions of the battery module. The cover plate assemblies provide electrical insulation and flame protection specifically at the front surface where terminals are located, while other surfaces may have different protection levels. This local quality approach maintains terminal accessibility while protecting the vulnerable front surface area.
Solution Approach 2:
The cover plate assemblies are constructed from composite materials that combine electrical insulation properties with flame resistance. This allows the protective structure to simultaneously address both electrical short-circuit prevention and thermal runaway protection, providing multi-functional protection at the exposed front surface.
3Reliability
If partition members are added to separate battery modules, then flame propagation prevention is improved, but device complexity increases
Solution Approach 1:
The partition members and cover plate assemblies are designed to perform multiple functions simultaneously: they provide flame propagation prevention, structural support for battery modules, electrical insulation barriers, and mechanical alignment features. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving reliable flame propagation prevention.
4Reliability
If cover plate assemblies are installed on all battery units, then protection against flame propagation is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The cover plate assemblies are designed as modular, segmented components that can be manufactured independently and assembled onto battery modules in a standardized manner. This segmentation enables parallel manufacturing processes and simplifies quality control, reducing overall manufacturing complexity despite the increased protection coverage.
Solution Approach 2:
The patent integrates the cover plate assembly with the existing battery module structure, combining multiple protective functions into a single integrated component rather than adding separate elements. This merging approach reduces the number of discrete parts and assembly steps, thereby limiting the increase in manufacturing complexity while achieving comprehensive flame propagation prevention.
Data Source
AI summary
An aspect of the current disclosure includes a battery pack including a plurality of battery units, each including a battery cell stack, and a terminal part provided on a front surface of the plurality of battery units and electrically connected to the battery cell stack, a pack housing including a battery unit mounting area and partition members configured to partition the battery unit mounting area into a plurality of parts, and cover plate assemblies coupled to the partition members while covering upper surfaces and the front surfaces of the plurality of battery units, wherein each battery unit of the plurality of battery units is accommodated in the battery unit mounting area between the partition members.