Battery Module Connector Shielding Against Thermal Runaway Fusion
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Solution Overview
Problem
Thermal runaway in one battery cell can cause a chain reaction leading to thermal runaway in the entire battery module, potentially resulting in external short circuits and safety hazards due to the fusion of connecting pieces and spraying of metal particles.
Innovation Solution
A battery module design featuring a protective layer with a melting point greater than the connecting piece, covering the connecting piece, circuit board, and output electrodes, made from insulating materials like mica paper or ceramic, to prevent fusion and short circuits, and a fixing layer to secure the protective layer in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connecting piece is made of metal to ensure electrical conductivity, then electrical connection between battery cells is achieved, but the connecting piece is prone to fusion during thermal runaway events
Solution Approach 1:
The patent introduces an insulating layer as an intermediary substance between the metal connecting piece and the battery cell terminals. This insulating layer has a melting point higher than the connecting piece material, serving as a protective mediator that prevents direct contact and fusion between the metal connecting piece and battery terminals during thermal runaway events, while still allowing electrical connection to function under normal operating conditions.
2Object-affected harmful factors
If the connecting piece is covered with protective material to prevent fusion, then thermal protection is improved, but electrical conductivity may be compromised
Solution Approach 1:
The insulating layer is applied locally and selectively around critical areas of the connecting piece, particularly at interfaces with battery terminals where fusion risk is highest. This localized protection approach ensures that electrical conductivity is maintained in non-critical areas while providing targeted thermal protection where it is most needed, balancing both requirements.
Solution Approach 2:
The patent changes the material parameter (melting point) of the protective layer to be higher than the connecting piece material. By selecting insulating materials with sufficiently high melting points, the protective layer can withstand thermal runaway temperatures without decomposing or losing its protective function, while still allowing electrical connection to operate at normal temperatures.
3Object-affected harmful factors
If a protective layer with higher melting point than connecting piece is used, then thermal protection is enhanced, but device complexity increases
Solution Approach 1:
The patent employs a uniform insulating layer with consistent material composition and properties throughout the battery module design. This homogeneous approach simplifies manufacturing processes and quality control compared to using different materials for different components, while still providing effective thermal protection across all connecting pieces.
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 prevents the connecting piece from fusing and contacting metal particles, reducing the risk of short circuits and chain thermal runaway, thereby enhancing the safety performance of the battery module and pack by maintaining the connecting piece's integrity and protecting critical components.
Implementation Method 1
a protective layer including a first protective portion being configured to cover the connecting piece, wherein a melting point of the first protective portion is greater than that of the connecting piece
Data Source
AI summary
A battery module, a battery pack, a device using a battery module as a power source, and a method of manufacturing a battery module are provided. The battery module includes: at least two battery cells; a connecting piece configured to electrically connect two battery cells of at least two battery cells; and a protective layer including a first protective portion configured to cover the connecting piece. A melting point of the first protective portion is greater than that of the connecting piece.