Battery Pack Protective Cap for Busbar Spark Isolation
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Solution Overview
Problem
Conventional battery packs are vulnerable to large fires due to sparks from short circuits directly contacting busbars, as the external terminals face the center of the pack case, leading to potential explosions.
Innovation Solution
A battery pack design featuring a protective cap that covers the busbars and external terminals, made of heat-resistant and insulating materials, to prevent direct contact with spark discharges, and includes a sheathing member to insulate the connecting busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the external terminals of cell assemblies face the center of the pack case, then the busbars can be easily connected to the external terminals, but the busbars become vulnerable to contact with scattered spark particles causing large fires
Solution Approach 1:
The patent introduces a protective cap as an intermediary component positioned between the spark source and the busbar. This cap covers the external terminals and busbars, preventing direct contact between scattered spark particles and the conductive elements while still allowing electrical connection to be made. The protective cap acts as a physical barrier that mediates the interaction between the cell assembly terminals and the busbar connection system.
Solution Approach 2:
The patent adds a spatial dimension to the protection system by extending the protective cap along the longitudinal direction of the pack case. This creates a three-dimensional protective structure that covers not only the terminal area but also the path where spark particles might travel. By extending protection in the longitudinal dimension, the system prevents spark contact without changing the fundamental front-facing orientation of the external terminals.
2Device complexity
If the busbars are gathered in the center of the pack case, then the electrical connection is simplified, but the structure becomes vulnerable to large fires from spark or flame
Solution Approach 1:
The protective cap serves as a mediator that allows the busbars to remain in the center position for simple electrical connections while introducing a protective barrier. This intermediary structure enables the busbar gathering arrangement to maintain its simplicity advantage while adding fire safety protection without requiring the busbars to be relocated to a different position.
Solution Approach 2:
The protective cap is made from composite materials that combine heat resistance and fire resistance properties. This allows the cap to withstand high temperatures and fire conditions while protecting the busbars, enabling the central busbar arrangement to maintain both simplicity and reliability.
3Reliability
If a protective cap is added to cover the busbars and external terminals, then fire safety is improved, but the device complexity increases
Solution Approach 1:
The protective cap is designed to perform multiple functions simultaneously: it protects the external terminals, covers the busbars, prevents spark contact, and provides structural support. By consolidating these multiple protective and structural functions into a single component, the design improves fire safety without proportionally increasing device complexity.
Solution Approach 2:
The patent merges the protection of external terminals and busbars into a single integrated protective cap structure. This consolidation combines multiple protective functions into one component rather than using separate protective elements, thereby improving fire safety while minimizing the increase in overall device 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 busbars from contacting spark discharges, minimizing the risk of fires and explosions by isolating the busbars and terminals, thereby enhancing safety.
Implementation Method 1
The protective cap may include a material having at least one of the properties of heat resistance and fire resistance
Implementation Method 2
The protective cap may include a material having at least one of the properties of heat resistance and fire resistance
Implementation Method 3
The pack case further includes a sheathing member positioned between the connecting busbars and the busbar cap and covering the upper part of the connecting busbars, wherein the sheathing member may include a material having insulating properties
Data Source
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AI summary
Disclosed herein relates to a battery pack for accommodating a cell assembly comprising a pair of external terminals, including: a pack case in which a cell assembly is seated, wherein the pack case includes: a base plate supporting a lower part of the cell assembly; and a protective cap coupled to a center part of the base plate, wherein the protective cap covers an external terminal of each cell assembly accommodated.