Battery Module Wire Venting Structure for Fire-Induced Short Circuits
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Solution Overview
Problem
Existing wires for electrical connections in battery modules are prone to insulation layer cracking and metal conductor exposure during fires, leading to unpredictable short circuits due to gas and liquid discharge through unspecified cracks.
Innovation Solution
A wire design featuring gas discharge members with flow grooves along the conductor, allowing controlled discharge of gas and liquid to both ends, preventing direct contact between the metal conductor and nearby components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional wire structure with insulative tube and heat resistant layer is used, then the wire can provide basic insulation and heat resistance, but the insulative tube cracks and heat resistant layer tears at unspecified positions during fire, causing unpredictable short circuits
Solution Approach 1:
The wire structure is segmented into functional zones: metal conductor core, insulative tube layer, and heat resistant covering layer. Each layer performs a specific protective function, with the heat resistant layer acting as a sacrificial barrier that deforms predictably to guide gas/liquid discharge away from the conductor, preventing short circuits while maintaining structural integrity of the core components
Solution Approach 2:
The heat resistant covering layer serves as an intermediary between the insulative tube and the external fire environment. It absorbs thermal stress and deforms in a controlled manner to redirect gas and liquid discharge paths, protecting the insulative tube from direct thermal damage and preventing unpredictable tearing that would expose the metal conductor
2Temperature
If the heat resistant layer is made thick to prevent tearing, then heat resistance improves, but the layer becomes heavier and more difficult to deform for guiding gas discharge
Solution Approach 1:
The wire employs composite material construction with the heat resistant covering layer made from materials specifically selected for their thermal properties and controlled deformability. The composition allows the layer to resist thermal degradation at fire temperatures while maintaining sufficient flexibility to deform and guide gas/liquid discharge, achieving both heat resistance and functional deformability without excessive weight
3Ease of operation
If the heat resistant layer is made thin and flexible for easy deformation, then gas discharge guidance improves, but the layer tears more easily at high temperatures
Solution Approach 1:
The heat resistant covering layer's material parameters are optimized to change predictably under thermal stress. The material is selected to undergo controlled softening and deformation at elevated temperatures, transitioning from a rigid protective state to a flexible guiding state that directs gas and liquid discharge away from the metal conductor while maintaining sufficient integrity to prevent random tearing
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
Prevents short circuits by ensuring controlled discharge of gases and liquids, maintaining insulation and conductor isolation even under high temperatures and fire conditions.
Implementation Method 1
the gas discharge member (220) is provided with a flow groove (221) allowing the gas and liquid to be discharged in a specific direction
Implementation Method 2
an insulative tube configured to cover the outer surface of the metal conductor to which the plurality of gas discharge members is added, and a highly refractory covering layer configured to cover the insulative tube
Implementation Method 3
When the temperature of a wire that electrically connects the battery cells to each other or electrically connects internal structures of the battery module or the battery pack to each other increases, the insulative tubes may be ceramized, whereby cracks may occur. Gas generated at this time
Data Source
AI summary
A wire for electrical connection may include a metal conductor located at the inner center thereof, a plurality of gas discharge members added to an outer surface of the metal conductor, the gas discharge members being disposed in a longitudinal direction of the metal conductor, an insulative tube configured to cover the outer surface of the metal conductor to which the plurality of gas discharge members is added, and a highly refractory covering layer configured to cover the insulative tube, whereby it is possible to prevent liquid and gas generated in the wire from being discharged in an unspecified direction in the event of fire.