Busbar Phase Change Composition for Battery Heat and Fire Control
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Solution Overview
Problem
Lithium secondary batteries experience rapid temperature increases during high-power operation, necessitating effective heat dissipation and passive propagation resistance to prevent thermal runaway, which current solutions are costly and inefficient.
Innovation Solution
A heat dissipation composition comprising a base resin and phase change material, with a specific weight ratio, applied to busbars to absorb latent heat and include a fire extinguishing agent, providing efficient heat dissipation and passive propagation resistance without separate fire extinguishing sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate heat dissipation structures and fire extinguishing sheets are added to battery packs, then heat dissipation performance and fire safety are improved, but material costs increase and manufacturing efficiency decreases
Solution Approach 1:
The patent combines heat dissipation function and fire extinguishing function into a single integrated composition applied to the busbar. The phase change material provides heat dissipation while the fire extinguishing agent provides fire suppression, eliminating the need for separate heat dissipation structures and fire extinguishing sheets, thereby reducing material costs and simplifying manufacturing processes
Solution Approach 2:
The heat dissipation composition serves multiple functions simultaneously: it acts as a thermal management solution through phase change heat absorption, provides fire safety through fire extinguishing agents, and maintains electrical insulation. This multi-functionality replaces what would traditionally require multiple separate components, improving manufacturing efficiency while maintaining reliability
2Reliability
If multiple separate components (heat dissipation structures and fire extinguishing sheets) are used, then heat dissipation and fire safety are achieved, but device complexity increases
Solution Approach 1:
The patent merges heat dissipation structures and fire extinguishing sheets into a single integrated heat dissipation composition applied to the busbar. This reduces the number of components from multiple separate parts to one unified composition, simplifying the overall device structure while maintaining both fire safety and heat dissipation functions
Solution Approach 2:
The composition performs multiple functions (heat dissipation, fire extinguishing, electrical insulation) that would traditionally require separate dedicated components. This multi-functionality reduces device complexity by eliminating the need for multiple specialized parts while achieving the same or better performance
3Ease of manufacture
If traditional heat dissipation methods are used without phase change material, then manufacturing is simpler, but heat dissipation performance is insufficient during high-power operation
Solution Approach 1:
The patent utilizes phase change material that absorbs heat through phase transition (melting) at a specific temperature range. This provides highly effective heat dissipation during high-power operation when traditional methods fail, while the composition can still be applied using simple coating methods, maintaining manufacturing simplicity while dramatically improving temperature control
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 composition effectively reduces busbar and surrounding cell temperatures, prevents fire propagation, and reduces manufacturing costs by integrating heat dissipation and fire suppression functions, enhancing safety and efficiency.
Implementation Method 1
A heat dissipation composition comprising a base resin and a phase change material, wherein a weight ratio of the base resin to the phase change material is from about 2.8:1 to about 1.3:1
Implementation Method 2
The composition effectively reduces busbar and surrounding cell temperatures
Data Source
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AI summary
A heat dissipation composition for busbars is disclosed. The heat dissipation composition includes a base resin and a phase change material, wherein a weight ratio of the base resin to the phase change material is from about 2.8:1 to about 1.3:1. Also disclosed are a method of manufacturing a busbar assembly, and an energy storage device comprising at least one busbar having the heat dissipation composition applied thereto.