Busbar Protective Member for Battery Thermal Propagation Delay
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Solution Overview
Problem
Battery cells generate significant heat during charging and discharging, which can lead to thermal runaway, causing flames or heat to spread to adjacent cells and resulting in damage.
Innovation Solution
A battery module design featuring a busbar assembly with a protective member made of fire-resistant materials and a fire-resistant member with refractory particles to delay thermal propagation and enhance heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are densely packed to increase energy density, then productivity and space utilization improve, but heat dissipation becomes difficult and thermal propagation risk increases
Solution Approach 1:
The battery module divides the internal space into multiple independent compartments using partition walls. Each compartment can contain individual battery cells or groups of cells, physically isolating them from each other. This segmentation prevents thermal runaway in one cell from propagating to adjacent cells, while still allowing high-density packing within each compartment.
Solution Approach 2:
Heat dissipation members are introduced as intermediary components between battery cells. These members facilitate thermal management by conducting heat away from individual cells or groups of cells, preventing temperature buildup that could lead to thermal runaway. The heat dissipation members act as a buffer zone that protects adjacent cells from thermal propagation.
2Reliability
If protective members with high melting point materials are added to prevent thermal propagation, then fire resistance improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The protective member integrates multiple functions into a single component: it includes a partition wall for spatial separation, a heat dissipation member for thermal management, and a protective member with high melting point material for fire resistance. By merging these functions, the design achieves comprehensive thermal protection without proportionally increasing structural complexity.
Solution Approach 2:
The protective member is designed as a multi-functional component that simultaneously provides thermal insulation, structural support, and fire resistance. The use of materials with high melting points (such as ceramic coatings or refractory materials) allows the same component to serve multiple protective roles, reducing the need for additional specialized parts.
3Temperature
If fire-resistant materials are used in protective members, then heat resistance improves, but manufacturing precision requirements increase due to material handling difficulties
Solution Approach 1:
The protective member uses materials with specifically selected thermal parameters (high melting points, low thermal conductivity) to achieve heat resistance. By carefully selecting materials whose properties match the thermal environment requirements, the design achieves effective thermal protection while maintaining compatibility with standard manufacturing processes. The material parameters are optimized to balance heat resistance with manufacturability.
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 design effectively suppresses the spread of heat and flames, prolonging the battery module's life and preventing damage to adjacent cells.
Implementation Method 1
a protective member disposed on at least a portion of one side of the busbar assembly facing the plurality of battery cells... the protective member may include a fire-resistant material
Implementation Method 2
the fire-resistant member may include a plurality of granular materials... effectively suppresses the spread of heat and flames
Data Source
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AI summary
The present disclosure relates to a battery module including: a plurality of battery cells; a busbar assembly disposed on one side of the plurality of battery cells and connected to the plurality of battery cells; and a protective member disposed on at least a portion of one side of the busbar assembly facing the plurality of battery cells.