Bottom Busbar Battery Pack Layout for Short-Circuit Suppression
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Solution Overview
Problem
Conventional battery devices are prone to external short circuits and explosions due to ignition of one cell stack causing adjacent cell stacks to short circuit, which poses a significant safety risk, especially in applications like electric vehicles.
Innovation Solution
A battery device design featuring a busbar assembly with conductive connection members embedded in an insulating body, positioned at the bottom of the case, which electrically connects cell stacks while minimizing top-side connections and maximizing space for venting flow paths, including a cooling system and partition walls to manage heat and gas discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cell stacks are electrically connected using conventional busbar assemblies, then electrical connectivity is achieved, but external short circuits may occur due to flame or high-temperature gas from ignited cells causing secondary ignition
Solution Approach 1:
The connection members are extracted from the top-side configuration and repositioned to contact terminals at the bottom of cell stacks. This extraction from the vulnerable top position removes the connection members from the hazard zone where flame and high-temperature gas propagate, preventing external short circuits while maintaining electrical connectivity
Solution Approach 2:
An insulating body is introduced as an intermediary component that embeds the connection members. This insulating body prevents direct exposure of conductive connection members to flame and high-temperature gas, acting as a protective barrier that maintains electrical connectivity while blocking the path of harmful thermal and chemical factors
2Reliability
If connection members are exposed to contact terminals, then electrical connection is achieved, but vulnerability to flame and high-temperature gas increases
Solution Approach 1:
The insulating body serves as a mediator that allows electrical connection to be achieved through embedded connection members while simultaneously protecting them from flame and high-temperature gas. The insulating material blocks thermal and chemical exposure while maintaining the electrical pathway
Solution Approach 2:
The connection configuration is moved from the top dimension (vulnerable to upward flame propagation) to the bottom dimension (protected from flame and gas). This dimensional relocation places connection members in a safer zone while maintaining their electrical connection function
3Volume of moving object
If cell stacks are arranged closely for compact design, then space utilization improves, but venting space for gas discharge is reduced
Solution Approach 1:
The case is segmented into multiple compartments using partition walls that create separate accommodation spaces for cell stacks. This segmentation allows gas generated from one cell stack to be contained and vented within its compartment, preventing gas accumulation and propagation to other stacks while maintaining compact overall design
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 suppresses external short circuits and explosions by ensuring secure electrical connections at the bottom, expanding venting space, and enhancing safety by reducing the risk of secondary ignition and improving heat dissipation and gas venting efficiency.
Implementation Method 1
a cooling plate including a first plate supporting the plurality of cell stacks, and a second plate coupled to the first plate to form a cooling flow path
Implementation Method 2
an insulating body embedding the connection member therein, wherein only the both end portions of the connection member are exposed from the insulating body externally to contact the terminal
Implementation Method 3
a venting flow path through which gas moves when the gas is discharged from the plurality of battery cells
Data Source
AI summary
A battery device including a plurality of cell stacks formed by stacking a plurality of battery cells and including terminal for external connection, a case accommodating the plurality of cell stacks therein, and at least one busbar assembly contacting the terminal of the plurality of cell stacks to electrically connect the plurality of cell stacks to each other, wherein the at least one busbar assembly is disposed in a bottom surface of the case, and wherein the plurality of cell stacks, having a bottom surface on which the terminal is disposed, is coupled to the busbar assembly, is disclosed.