Battery Module Terminal Isolation Against Thermal Runaway Shorts
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Solution Overview
Problem
Existing battery modules face the risk of electrical short circuits due to high-temperature gases, flames, or foreign substances emitted from battery modules, which can lead to thermal runaway and explosion.
Innovation Solution
A battery module design featuring an insulating cover with a support for terminals, a blocking structure, and an end plate configuration that isolates and protects the terminals from the end plate, using fire-resistant materials and a blocking structure to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the terminal is disposed on the outer surface of the metal case to be electrically connected to battery cells, then electrical connection is simplified, but the insulating structure supporting the terminal may melt or collapse when exposed to high-temperature gases or flames, resulting in electrical short circuit
Solution Approach 1:
The patent introduces an insulating cover as an intermediary component between the terminal and the external environment. This insulating cover includes an insulating case that covers the terminal and extends to cover openings in the end plate, preventing direct contact between high-temperature gases/flames and the terminal support structure. The insulating case acts as a protective mediator that maintains electrical isolation even under thermal stress conditions.
Solution Approach 2:
The insulating cover is installed beforehand to protect the terminal support structure from potential thermal damage. By providing this protective layer in advance, the design prevents the insulating structure from melting or collapsing when exposed to high-temperature gases or flames from battery cell failures or adjacent modules.
2Quantity of substance
If multiple battery cells are densely disposed in a limited space to increase energy density, then energy density is improved, but the risk of thermal runaway and thermal propagation between battery cells increases
Solution Approach 1:
The patent divides the battery module into segmented zones using the insulating cover and insulating case. The terminal area is segmented and isolated from the battery cell array by the insulating cover, creating a separate protective zone. This segmentation prevents thermal propagation from battery cells to the terminal structure and vice versa, while still allowing dense packing of battery cells within the module.
Data Source
AI summary
A battery module includes a module frame having an inner space in which a plurality of battery cells is accommodated and an opening leading to the inner space; an insulating cover including a support on which a terminal electrically connected to the plurality of battery cells is disposed and supported, and configured to primarily cover the opening; an end plate having a window through which the support is exposed to the outside and configured to secondarily cover the opening covered by the insulating cover; and a blocking structure configured to cover the support exposed through the window and block an electrical short circuit between the terminal disposed on the support and the end plate.