Battery Module Busbar Opening Seal for Thermal Runaway Containment
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Solution Overview
Problem
Lithium secondary battery modules in battery packs face challenges in suppressing the propagation of thermal runaway phenomena, which can lead to high-temperature gas and flame ejection, potentially causing ignition or explosion, especially in densely packed configurations like those in electric vehicles.
Innovation Solution
A battery module design featuring a blocking member that surrounds the terminal busbar, moving to close the gap between the busbar and an opening in the end plate as internal pressure rises, thereby preventing the ejection of high-temperature gas and flame. The blocking member includes a body portion and an extension portion that form a stepped structure to effectively seal the gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are stacked to form a battery module, then capacity and output are improved, but heat dissipation becomes difficult and thermal runaway propagation risk increases
Solution Approach 1:
The battery module is divided into multiple battery cell stacks, with each stack being an independent enclosed space. This segmentation isolates thermal issues to individual stacks, preventing heat accumulation across the entire module and facilitating localized heat dissipation while maintaining high overall output capacity.
Solution Approach 2:
An insulating cover is introduced as an intermediary component between adjacent battery cell stacks. This insulating cover acts as a thermal barrier, reducing heat transfer between stacks and preventing thermal runaway propagation, thereby enabling safer operation of high-capacity battery modules.
2Quantity of substance
If battery modules are densely arranged to increase vehicle mileage, then energy density is improved, but thermal runaway propagation between modules increases
Solution Approach 1:
Each battery cell stack is enclosed as a separate unit within the battery module, creating physical segmentation that limits thermal runaway propagation. This allows dense arrangement of multiple stacks to increase energy density while maintaining safety through isolated containment of each stack.
Solution Approach 2:
Insulating covers are pre-installed between adjacent battery cell stacks to provide thermal cushioning before thermal runaway can occur. This preventive measure reduces heat transfer between stacks, cushioning against potential thermal propagation and enabling safer dense packing of battery modules.
3Ease of operation
If an opening is provided in the end plate for terminal busbar access, then electrical connectivity is improved, but high-temperature gas and flame ejection risk increases
Solution Approach 1:
A blocking member is introduced as an intermediary component at the opening in the end plate. This blocking member selectively prevents high-temperature gas and flame ejection through the opening while allowing terminal busbar access, thereby resolving the contradiction between electrical connectivity and safety.
Solution Approach 2:
The blocking member is positioned specifically at the opening region where flame ejection risk exists, providing localized protection without affecting overall terminal access. This local quality approach maintains ease of operation for terminal connectivity while preventing harmful effects at the specific vulnerable location.
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 cancels the ejection of high-temperature gas and flame, preventing the propagation of thermal runaway from one battery module to others and reducing the risk of explosion or ignition within the battery pack.
Implementation Method 1
upon a rise of internal pressure of the module frame, the blocking member moves to close a gap between the opening and the terminal busbar
Data Source
AI summary
A battery module includes a battery cell stack in which a plurality of battery cells are stacked; a module frame that houses the battery cell stack; end plates located on one side and the other side of the battery cell stack and having an opening formed therein; a terminal busbar exposed through the opening; and a blocking member that surrounds the terminal busbar, wherein upon the rise of internal pressure of the module frame, the blocking member moves to close a gap between the opening and the terminal busbar.