Ceramicized Bus Bar Cap for Battery Pack Fire Insulation
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Solution Overview
Problem
Conventional bus bar caps in battery packs are not fire-resistant, leading to electrical short circuits and flame spread when high temperatures occur, necessitating a solution for maintaining thermal and electrical insulation.
Innovation Solution
A fire-resistant bus bar cap featuring a cap body made of ceramicized fire-resistant silicone with a protective layer, designed to cover bus bars and electrical connection parts, ensuring insulation and airtightness even at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a soft rubber cap is used to cover the bus bar, then the cap is easy to manufacture and install, but the insulating properties are low and it is vulnerable to impact and melting at high temperatures
Solution Approach 1:
The patent uses a composite structure consisting of a silicone rubber base layer and a fire-resistant silicone outer layer. The fire-resistant silicone contains inorganic fillers (such as aluminum hydroxide, magnesium hydroxide, or silica) that provide high-temperature resistance and maintain insulating properties up to 800°C or higher, while the underlying silicone rubber provides flexibility and ease of installation. This composite material approach resolves the contradiction between ease of manufacture and reliability at high temperatures.
2Reliability
If a fire-resistant silicone ceramicized at high temperatures is used for the cap body, then thermal and electrical insulation is maintained at high temperatures, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies parameter changes by ceramicizing the fire-resistant silicone through controlled heating to high temperatures (typically 500-800°C or higher). This thermal treatment transforms the silicone material into a ceramicized state that maintains dimensional stability, insulating properties, and structural integrity at high temperatures. The ceramicization process converts organic silicone into an inorganic ceramic structure, fundamentally changing the material parameters to achieve fire resistance while managing the manufacturing complexity through a standardized heat treatment process.
3Reliability
If the bus bar components are designed to be thermally and electrically insulated, then safety is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into the bus bar cap structure. The cap simultaneously provides: (1) electrical insulation between the bus bar conductor and surrounding components, (2) thermal insulation to prevent heat transfer, (3) mechanical protection through impact resistance, and (4) flame containment. By integrating these multiple protective functions into a single cap component rather than using separate elements for each function, the patent improves safety while minimizing the increase in device complexity.
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 fire-resistant bus bar cap effectively maintains insulation and airtightness, preventing electrical short circuits and flame spread, while ensuring the bus bar and electrical connection parts remain thermally and electrically insulated.
Implementation Method 1
a cap body of a fire-resistant silicone that includes therein an insertion space of a fastening member for fastening the bus bar and the electrical connection part and is ceramicized at high temperatures
Data Source
AI summary
A fire-resistant bus bar cap of the present technology is a bus bar cap covering a bus bar and an electrical connection part coupled to the bus bar, and includes a cap body of a fire-resistant silicone that includes therein an insertion space of a fastening member for fastening the bus bar and the electrical connection part and a protective layer covering the cap body of the fire-resistant silicone. A battery pack of the present technology includes the fire-resistant bus bar cap.