Ceramicizing Fire-Resistant Cable Structure for Battery Pack Insulation
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Solution Overview
Problem
Existing cables used in battery packs fail to maintain thermal and electrical insulation at high temperatures, leading to electrical short circuits and flame propagation due to melting of plastic resin sheaths, and are prone to damage from sharp edges and assembly challenges.
Innovation Solution
A fire-resistant cable featuring a ceramicized silicone sheath layer and a metal case that accommodates the cable core wire, with both ends exposed through openings, providing insulation and protection even at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic resin sheath layer is used for cable insulation, then the cable is flexible and easy to manufacture at normal temperatures, but the sheath layer melts completely at high temperatures causing electrical short circuits
Solution Approach 1:
The patent uses a composite structure combining plastic resin sheath layer with heat-resistant materials (mica sheet, glass fiber, or heat-resistant silicone) to create a multi-layered cable covering. This composite approach allows the cable to maintain flexibility and ease of manufacture from the plastic resin while the heat-resistant materials provide fire resistance and prevent melting at high temperatures.
2Reliability
If heat-resistant silicone or mica sheet is used for the sheath layer, then fire resistance is improved, but thermal propagation cannot be sufficiently prevented at extremely high temperatures
Solution Approach 1:
The patent combines multiple heat-resistant materials (mica sheet, glass fiber, and/or heat-resistant silicone) in a composite multi-layered structure. This composite approach creates synergistic effects where the combination of materials provides superior thermal resistance and fire protection compared to single materials, effectively preventing thermal propagation even at extremely high temperatures up to 1000°C or higher.
3Ease of operation
If the cable sheath layer is made thin for flexibility, then ease of operation is improved, but the insulating properties are compromised
Solution Approach 1:
The patent divides the cable covering into multiple segmented layers: an inner plastic resin sheath layer for flexibility and ease of operation, and outer heat-resistant material layers (mica sheet, glass fiber, or heat-resistant silicone) for insulation and fire resistance. This segmentation allows each layer to perform its specific function optimally - the thin plastic resin provides flexibility while the outer heat-resistant layers provide insulation and protect against thermal propagation.
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 cable maintains insulation and airtight properties, prevents deformation, and enhances electrical safety by using a ceramicized silicone sheath and a metal case that protects against mechanical damage and sharp edges, allowing for easy assembly and bending.
Implementation Method 1
a fire-resistant silicone sheath layer surrounding portions of the cable core wire excluding both ends thereof and ceramicized at high temperatures to support the cable core wire
Data Source
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AI summary
The present technology provides a fire-resistant cable including a cable core wire, a fire-resistant silicone sheath layer surrounding portions of the cable core wire excluding both ends thereof and ceramicized at high temperatures to support the cable core wire, and a metal case accommodating the cable core wire and the fire-resistant silicone sheath layer, wherein both sides of the metal case are provided with openings through which the both ends of the cable core wire are drawn out to the outside. The present technology also provides a battery pack including the fire-resistant cable.