CCU Busbar Clamping and Heat Shields for Battery Cell Venting
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Solution Overview
Problem
Existing battery systems face challenges in safely managing thermal runaway of battery cells, which can lead to thermal propagation and fire due to the discharge of hot venting gas streams that can ignite adjacent cells.
Innovation Solution
A battery system design incorporating a cell contacting unit (CCU) with a carrier and busbars that exert a clamping force, a heat-resistant protection cover, and elastic members to prevent gaps and contain venting gas, using materials like mica and aerogel to provide thermal insulation and reduce the risk of thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a venting valve is disposed on the terminal side of battery cells to release venting gas during thermal runaway, then the battery cell can be protected from internal pressure buildup, but hot venting gas streams can flow into tolerance gaps below the cell contacting unit and ignite adjacent cells
Solution Approach 1:
A heat-resistant protection cover (made of mica or aerogel) is introduced as an intermediary component between the battery cells and the cell contacting unit carrier. This mediator blocks the harmful hot venting gas streams from reaching the tolerance gaps below the carrier, preventing thermal propagation to adjacent cells while allowing the venting valve to continue its pressure relief function
Solution Approach 2:
The invention converts the harmful hot venting gas streams into a controlled pathway by directing them through designated venting channels in the protection cover. The heat-resistant material withstands the thermal exposure and channels the gas safely, transforming a dangerous uncontrolled release into a managed thermal management system
2Reliability
If the cell contacting unit carrier is positioned close to battery cells to ensure electrical contact, then electrical conductivity is improved, but tolerance gaps may form that allow hot venting gas to penetrate and cause thermal runaway in adjacent cells
Solution Approach 1:
The heat-resistant protection cover serves as a protective intermediary layer between the battery cells and the cell contacting unit carrier. It fills and seals the tolerance gaps that inherently exist due to tight positioning requirements, blocking hot venting gas penetration while maintaining the close proximity needed for electrical conductivity
Solution Approach 2:
The protection cover is made from advanced composite or ceramic materials (mica or aerogel) that possess both heat resistance and sealing properties. These materials can withstand extreme temperatures while maintaining structural integrity to close tolerance gaps, providing dual functionality of thermal protection and gas sealing
3Temperature
If heat-resistant materials like mica and aerogel are used to insulate against venting gas, then thermal insulation performance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
Instead of making the entire cell contacting unit from heat-resistant materials, the invention applies heat-resistant protection covers only at the specific locations where thermal exposure occurs (between cells and carrier). This localized application provides necessary thermal insulation while keeping the rest of the structure made from conventional, easier-to-manufacture materials
Solution Approach 2:
The protection system is segmented into separate, modular heat-resistant covers for each battery cell position. This segmentation allows for simplified manufacturing of individual components that can be assembled into the complete battery pack, reducing overall manufacturing complexity compared to creating a single complex heat-resistant structure
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 seals and insulates against hot venting gas, reducing the risk of thermal propagation and cell infection, enhancing safety and preventing adjacent cell ignition.
Implementation Method 1
the busbars each includes an elastic member configured to exert a clamping force on the CCU carrier
Implementation Method 2
using materials like mica and aerogel to provide thermal insulation and reduce the risk of thermal runaway
Data Source
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AI summary
The present disclosure refers to a battery system (100). The battery system (100) includes a battery pack (10), a cell contacting unit, CCU, carrier (18) and a plurality of busbars (20). The battery pack (10) includes a plurality of battery cells (12) each having a pair of electrode terminals (14) and a venting valve (16) disposed on a terminal side of the battery cells (12). The terminal side of the battery cells (12) faces a first side of the battery pack (10) along a z-direction. The CCU carrier (18) is disposed on the terminal side of each of the battery cells (12). The plurality of busbars (20) is disposed on the electrode terminals (14) of the battery cells (12) and is in mechanical contact with the CCU carrier (18). The busbars (20) each includes an elastic member (22) configured to exert a clamping force on the CCU carrier (18).