Busbar Gas Outlet for Battery Module Thermal Safety
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Solution Overview
Problem
Battery modules lack an effective structure to rapidly discharge gases externally, leading to a risk of thermal propagation and ignition between adjacent cells, as existing venting systems are insufficient in managing high-temperature gases and flames.
Innovation Solution
A battery module design featuring a busbar assembly with a gas outlet and venting member that directs gas away from the cell stack, combined with a filler material for heat resistance and a thermal propagation blocking member to prevent heat and flame diffusion, ensures rapid gas discharge and minimizes thermal propagation between cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If gas discharge structure is added to busbar assembly, then gas discharge speed is improved, but device complexity increases
Solution Approach 1:
The gas outlet is integrated directly into the busbar assembly structure, merging the electrical connection function with the gas discharge function in a single component rather than adding separate venting systems
Solution Approach 2:
The busbar assembly serves dual purposes: electrical connection through the busbar and gas discharge through the integrated outlet, allowing one component to perform multiple functions
2Reliability
If venting member is added to module housing, then thermal propagation prevention is improved, but device complexity increases
Solution Approach 1:
The venting member is designed as a separate, removable component that can be independently installed in the module housing, allowing it to be extracted or adjusted without modifying the entire housing structure
Solution Approach 2:
The venting member acts as an intermediary component between the internal cell environment and external atmosphere, providing a controlled interface for gas discharge and thermal management
3Productivity
If gas outlet is formed in busbar assembly, then gas discharge efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The gas outlet is designed as a distinct feature within the busbar assembly that can be separately formed or positioned, allowing independent optimization of its location and dimensions without redesigning the entire assembly
Solution Approach 2:
The gas outlet position is predetermined in the busbar assembly design, allowing for pre-positioning and alignment features that simplify assembly and reduce precision requirements during final installation
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 solution effectively reduces the risk of thermal propagation and ignition by rapidly discharging gases and using heat-resistant materials to contain and direct gas discharge, thereby enhancing safety and module stability.
Implementation Method 1
a busbar assembly having an electrically conductive busbar electrically connected to the electrode lead, wherein a gas outlet discharging gas generated within the plurality of battery cells in an outward direction of the cell stack is formed in the busbar assembly
Implementation Method 2
a thermal propagation blocking member blocking diffusion of heat or flames between the plurality of battery cells
Data Source
AI summary
Systems and methods are provided for a battery module. A battery module includes a module housing configured to hold a cell stack comprising a plurality of battery cells. A busbar assembly having an electrically conductive busbar is configured for electrical connection to electrode leads of the battery cells. The busbar assembly includes a gas outlet configured for discharging gas generated within the plurality of battery cells in a direction away from the cell stack, and the module housing includes a venting member configured to vent the gas discharged from the gas outlet to an outside of the module housing.