Ceramicizing Fire-Resistant Bus Bar Covering for Battery Pack Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bus bars in battery packs lack sufficient fire resistance and insulation, leading to electrical short circuits and flame propagation when exposed to high temperatures, and their assembly is cumbersome due to the use of soft rubber caps and tapes.
Innovation Solution
A fire-resistant bus bar with a ceramicized fire-resistant silicone covering and a protective layer, featuring a cap part and body covering part integrally formed, and a through-hole for fastening, which maintains insulation and airtightness even at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a soft rubber cap is used to cover the bus bar ends, then the bus bar is easy to assemble, but the insulating properties are low and the cap is vulnerable to impact at high temperatures
Solution Approach 1:
The patent changes the material parameter from soft rubber to fire-resistant silicone rubber, which maintains flexibility for easy assembly while adding high-temperature resistance and improved insulating properties. The material transition allows the cap to retain ease of operation while significantly improving reliability under thermal stress.
Solution Approach 2:
The patent uses composite material construction by combining fire-resistant silicone rubber with heat-resistant protective coatings or layers. This composite approach maintains the flexibility and ease of assembly of rubber materials while adding the thermal stability and insulating properties needed for high-temperature environments.
2Ease of manufacture
If a wear-resistant tape is used to attach the cap to the bus bar, then the bus bar can be connected, but the tape melts at high temperatures causing separation
Solution Approach 1:
The patent extracts and removes the wear-resistant tape from the assembly, replacing it with a integrated connection design where the fire-resistant silicone rubber cap is directly attached to the bus bar body. This eliminates the tape component that melts at high temperatures while maintaining the ease of connection through the flexible nature of the silicone rubber material.
Solution Approach 2:
The patent merges the cap and bus bar into a single integrated component made of fire-resistant silicone rubber, eliminating the need for separate attachment materials like tape. This unified structure ensures consistent fire-resistant performance throughout the entire assembly while simplifying the connection process.
3Ease of manufacture
If general silicone rubber or epoxy is used for the covering layer, then the bus bar can be covered, but the covering layer melts at very high temperatures exposing the conductor
Solution Approach 1:
The patent changes the material parameter from general silicone rubber or epoxy to fire-resistant silicone rubber with a significantly elevated fire-resistant temperature range (500-800°C or higher). This material substitution maintains the ease of covering and manufacturing while dramatically improving the temperature resistance to prevent melting and conductor exposure during fire conditions.
4Ease of manufacture
If the cap and body covering are made separately and assembled with tape, then manufacturing is simple, but productivity decreases due to cumbersome assembly
Solution Approach 1:
The patent merges the cap and body covering into a single integrated fire-resistant silicone rubber component that is molded as one piece. This integration eliminates the need for separate assembly steps involving tape attachment, thereby maintaining manufacturing simplicity while dramatically improving productivity by reducing assembly time and complexity.
Solution Approach 2:
The integrated fire-resistant silicone rubber component serves multiple functions simultaneously: it provides the cap covering, the body covering, and the attachment function all in one element. This multi-functionality simplifies the manufacturing process and improves productivity by eliminating redundant assembly operations.
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 maintains thermal and electrical insulation, prevents short circuits, and simplifies assembly by integrating the cap and body covering parts, enhancing connection strength and reducing damage from external forces.
Implementation Method 1
a fire-resistant silicone covering including a cap part covering opposite ends of the bus bar conductor part, and a body covering part integrally coupled to the cap part while covering a body of the bus bar conductor part between the opposite ends, the fire-resistant silicone covering being ceramicized at high temperatures
Data Source
AI summary
A fire-resistant bus bar having a bus bar conductor, a fire-resistant silicone covering including a cap covering opposite ends of the bus bar conductor, and a body covering part integrally coupled to the cap while covering a body of the bus bar conductor between the opposite ends, the fire-resistant silicone covering being ceramicized at high temperatures to support the bus bar conductor; and a protective layer covering the fire-resistant silicone covering is a provided. A through-hole is formed in the cap to extend from an upper surface of the cap to a surface of the cap in contact with the bus bar conductor, and a battery pack comprising the fire-resistant bus bar.