Refractory Silicone Busbar Cover for Fire and Dust Protection
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Solution Overview
Problem
Existing busbar assemblies in battery packs are prone to melting during flames, leading to potential short circuits and explosions due to exposure, and accumulate dust, which can cause further electrical issues.
Innovation Solution
A busbar assembly with a protective cover made of refractory silicone and protruding wing portions that cover through holes, ensuring electrical insulation and preventing dust accumulation, even in high-temperature environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional sheath and cap structure is used to protect the busbar, then the busbar is covered and provides some protection, but the structure melts during flames exposing the busbar and causes dust accumulation at coupling portions
Solution Approach 1:
The protective cover is made of refractory silicone, a composite material that combines the properties of silicone rubber with refractory characteristics. This material maintains flexibility for dust prevention while providing fire resistance to prevent melting during flames, resolving the contradiction between fire resistance and dust accumulation protection
Solution Approach 2:
The protective cover includes protruding wing portions that specifically cover coupling holes where dust accumulates, while the main body provides fire resistance. This localized functional differentiation addresses both dust accumulation at coupling portions and overall fire resistance without compromising either property
2Reliability
If the protective cover is made of fire-resistant material, then fire resistance is improved, but the material must maintain flexibility to prevent dust accumulation
Solution Approach 1:
Refrawatory silicone combines the fire-resistant properties of refractory materials with the flexibility and sealing capabilities of silicone rubber. This composite material can deform to seal coupling holes for dust prevention while maintaining structural integrity during fire exposure
Solution Approach 2:
The refractory silicone material undergoes parameter changes at different temperatures: at normal temperatures it remains flexible to seal coupling holes and prevent dust accumulation, while at high temperatures it maintains fire resistance to prevent melting and exposure of the busbar
3Ease of operation
If through holes are exposed for electrical connection, then electrical connection is enabled, but dust accumulates in the holes causing short circuits
Solution Approach 1:
The protective cover is segmented into a main body portion and protruding wing portions. The wing portions specifically extend to cover coupling holes while the main body provides overall protection. This segmentation allows electrical connection through the holes while preventing dust accumulation that would cause short circuits
Solution Approach 2:
The protruding wing portions act as an intermediary structure between the exposed through holes and the external environment. They allow electrical connection to pass through the holes while serving as a barrier to prevent dust from entering and accumulating in the coupling portions
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
Maintains electrical insulation and prevents dust accumulation, reducing the risk of short circuits and explosions in battery packs by using refractory silicone and wing portions to protect the busbar assembly.
Implementation Method 1
A busbar assembly with a protective cover made of refractory silicone and protruding wing portions that cover through holes, ensuring electrical insulation and preventing dust accumulation, even in high-temperature environments
Data Source
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AI summary
A busbar assembly according to an exemplary embodiment of the present invention includes a busbar including a body portion extending in a first direction and end portions located at both ends of the body portion in the first direction and having through holes formed therein, and a protective cover including a cover portion surrounding the busbar, and a plurality of wing portions protruding from the cover portion in a second direction intersecting the first direction.