Battery Pack Reinforcing Member Layout for Thermal Runaway Protection
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Solution Overview
Problem
Existing battery packs for vehicles lack sufficient rigidity and effective protection for electrical and communication components from flames during thermal runaway events, leading to potential damage and flame propagation.
Innovation Solution
A battery pack design featuring a reinforcing member assembly with a base member, bus bar, connection groove, wire, and member cover, which embeds the bus bar and wire to enhance rigidity and protect components from flames, including a configuration where the member cover blocks external exposure and suppresses flame propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing members are added to improve rigidity of the battery case, then the rigidity is improved, but the device complexity increases
Solution Approach 1:
The bus bar is integrated with the base member through direct coupling, eliminating the need for separate mounting structures. The connection groove is formed directly in the base member, combining the mounting function with the structural member itself, thereby improving rigidity without adding complex components.
Solution Approach 2:
The base member serves multiple functions: it provides structural support for rigidity, contains the connection groove for wire management, and couples with the bus bar for electrical connection. This multi-functionality reduces the need for separate reinforcing members while maintaining structural integrity.
2Volume of moving object
If components for electrical connection and communication are compacted, then the space utilization is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The connection groove is pre-formed in the base member with precise dimensions and positioning. The bus bar mounting groove is also pre-configured, allowing components to be assembled in a straightforward manner without requiring high-precision field adjustments, thus achieving compact integration while maintaining manufacturability.
3Object-affected harmful factors
If the member cover blocks the connection groove and bus bar mounting groove, then protection from flames is improved, but the device complexity increases
Solution Approach 1:
The member cover is coupled directly to the base member, integrating the protective function with the existing structural framework. This single coupling action provides flame protection for both the connection groove and bus bar mounting groove simultaneously, improving safety without adding multiple separate protective components.
4Reliability
If heat-resistant materials are used to protect components from thermal runaway, then the reliability is improved, but the weight increases
Solution Approach 1:
The member cover acts as a protective shell that can be made from heat-resistant materials. By using a cover structure rather than fully encapsulating components in heavy fireproofing materials, the patent achieves flame protection while minimizing weight increase through a thin-film approach.
Data Source
AI summary
A battery pack for a vehicle includes: a base member forming a skeleton, a bus bar mounted on the base member, a connection groove formed by being depressed in the base member, a wire inserted into the connection groove, and a member cover coupled to the base member to block the bus bar and the connection groove from the outside.