Busbar Firewall Assembly to Delay Flame Penetration
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Solution Overview
Problem
Existing busbar assemblies in battery packs are vulnerable to flame penetration between the busbar body and the heat-resistant member during a fire, leading to premature ceramization and increased risk of short circuits.
Innovation Solution
A busbar assembly with a firewall coupled to the outer surface of the busbar body adjacent to the electrical connection portion, and a heat-resistant member encasing the firewall and the busbar body, except for the electrical connection portions, to delay flame penetration and ceramization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heat-resistant member encases the busbar body, then electrical insulation is improved, but flame penetration between the busbar body and heat-resistant member causes premature ceramization and short circuit risk
Solution Approach 1:
A firewall member is introduced as an intermediary component between the busbar body and the heat-resistant member. This firewall prevents direct flame penetration to the heat-resistant member while maintaining the electrical insulation function, thereby resolving the contradiction between insulation reliability and flame resistance.
Solution Approach 2:
The protective structure is segmented into multiple functional layers: the heat-resistant member for thermal protection, the firewall member for flame barrier function, and the insulating tape for electrical insulation. This segmentation allows each component to specialize in one protective function, preventing flame penetration while maintaining overall reliability.
2Device complexity
If the heat-resistant member is directly attached to the busbar body, then structural simplicity is maintained, but flame exposure accelerates ceramization and causes short circuits
Solution Approach 1:
The protective structure is divided into distinct functional segments: the firewall member wrapped around the busbar body provides flame protection, while the heat-resistant member encases the firewall for thermal resistance. This segmentation adds a component but enables specialized fire resistance functionality.
Solution Approach 2:
The firewall member serves as an intermediary layer between the busbar body and the heat-resistant member, preventing flame from directly exposing the heat-resistant member and busbar body, thereby enhancing fire resistance without compromising structural integrity.
3Reliability
If the insulating tape covers the busbar body, then electrical insulation is provided, but flame damage opens the insulating tape and exposes the busbar body
Solution Approach 1:
The protective system is segmented into three layers with distinct functions: the insulating tape for electrical insulation, the firewall member for flame barrier protection, and the heat-resistant member for thermal resistance. This segmentation allows the firewall to protect the insulating tape from flame damage while maintaining insulation functionality.
Solution Approach 2:
The firewall member is applied beforehand to the busbar body to provide flame protection. This prior cushioning prevents flame from directly damaging the insulating tape and busbar body, thereby maintaining electrical insulation strength even under fire conditions.
4Ease of operation
If the busbar body is exposed at electrical connection portions, then electrical connection functionality is maintained, but flame can penetrate and cause short circuits
Solution Approach 1:
The protective structure is segmented to provide differential protection: the firewall member covers the busbar body except at the electrical connection portions, allowing electrical functionality while providing flame protection where needed. The heat-resistant member then encases the entire assembly for comprehensive thermal protection.
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 firewall effectively blocks flame penetration, delaying the ceramization of the heat-resistant member and minimizing exposure of the busbar body, thereby reducing the risk of short circuits and enhancing safety.
Implementation Method 1
the firewall effectively blocks flame penetration, delaying the ceramization of the heat-resistant member
Implementation Method 2
delaying the ceramization of the heat-resistant member and minimizing exposure of the busbar body
Data Source
AI summary
A busbar assembly includes a busbar body, a firewall, and a heat-resistant member. The busbar body has an electrical connection portion formed at each end thereof and the firewall is coupled to an outer surface of the busbar body adjacent to the electrical connection portion. The heat-resistant member encloses the firewall and the outer surface of the busbar body excluding the electrical connection portion so that the penetration of flames between the heat-resistant member and the busbar body is delayed, and the safety of the busbar assembly is improved.