Insulating Tube Battery Pack Structure for Impact and Short-Circuit Isolation
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Solution Overview
Problem
Battery packs used in medium and large devices are prone to internal short circuits and accidents due to external impact, which can lead to explosions or fires, as the metal pack housing deforms and collides with internal components.
Innovation Solution
A battery pack design featuring a module case with an insulating tube that surrounds the outer wall, providing embossing structures for impact absorption and a heat-shrinkable material to secure the cases together, along with a pack housing that contacts the embossing structures for enhanced cooling and durability, and a fastening system to prevent internal component shaking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal pack housing is used to protect secondary batteries from external impact, then protection capability is improved, but internal short circuit risk increases due to deformation and collision with internal components
Solution Approach 1:
An insulating tube is introduced as an intermediary component between the metal pack housing and the internal components (secondary batteries and bus bar). The tube surrounds the module case and extends along the bus bar, preventing direct contact between conductive components while the metal housing provides structural protection. This mediator resolves the contradiction by maintaining protection capability while eliminating the short circuit risk caused by metal deformation.
2Duration of action of stationary object
If the pack housing is made of metal material, then durability is improved, but heat dissipation efficiency decreases due to insulation requirements
Solution Approach 1:
The insulating tube is selectively applied only where electrical insulation is needed (surrounding the module case and extending along the bus bar), while the metal pack housing maintains full thermal contact with the battery modules in other areas. This localized application preserves heat dissipation efficiency through the durable metal housing while providing insulation only where required for safety.
3Reliability
If an insulating tube is added to prevent internal short circuit, then safety is improved, but device complexity increases
Solution Approach 1:
The insulating tube is implemented as a flexible, thin-walled protective covering that can be easily fitted around the module case and bus bar. This simple tubular structure provides comprehensive insulation without requiring complex assembly or additional components, maintaining ease of manufacturing while significantly improving safety.
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 insulating tube effectively prevents external electrical contact and absorbs impact, increasing safety and durability by minimizing internal component damage and facilitating efficient heat dissipation, while reducing manufacturing costs and weight.
Implementation Method 1
the insulating tube 230 may include a heat shrinkable material that is heat shrunk such that the first case 212 and the second case 214 are tightly fixed to each other
Implementation Method 2
it is possible to effectively absorb external impact, and minimizing the impact on the internal components accommodated therein
Implementation Method 3
heat generated due to charging and discharging of a plurality of secondary batteries, which are internal components may effectively conduct even the module case, the insulating tube and the pack housing, thereby effectively increasing the cooling efficiency of the battery pack
Data Source
AI summary
A battery pack that protects an internal configuration from external impact and effectively prevents internal short circuit is disclosed. The battery pack includes a plurality of can type secondary batteries arranged to be laid down in a horizontal direction; a bus bar at least partially formed of an electrically conductive material to electrically connect the plurality of can type secondary batteries; at least one module case with an empty space formed inside to accommodate the plurality of can type secondary batteries; and an insulating tube configured to surround an outer wall of the module case and having an outer surface on which a plurality of embossing structures with a part bulging in an outer direction are formed.