Battery Module Connector Sealing Against Flame Discharge
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Solution Overview
Problem
Thermal runaway in battery modules can lead to flame discharge through assembly gaps, causing safety hazards such as explosions due to thermal propagation.
Innovation Solution
A connector assembly with a cover part surrounding the connector to seal gaps, using high heat-resistant materials like silicone or rubber, and a rib structure conforming to the casing's rib groove to prevent flame discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector is exposed through the connector insertion portion for electrical connection, then ease of operation is improved, but safety deteriorates due to flame discharge through assembly gaps
Solution Approach 1:
A cover part made of heat-resistant material (silicone or rubber) is introduced as an intermediary component between the connector and the external environment. This cover part surrounds the outer peripheral surface of the connector and seals the gap between the connector and the connector insertion portion, preventing flame discharge while allowing the connector to remain exposed for electrical connection operations.
Solution Approach 2:
The cover part is constructed from flexible heat-resistant materials such as silicone or rubber. These materials can deform elastically under thermal stress while maintaining the sealing function, preventing flame discharge through the gap around the connector without compromising the ease of connector insertion or removal.
2Object-affected harmful factors
If high heat-resistant materials are used for the cover part, then safety is improved by preventing flame discharge, but device complexity increases
Solution Approach 1:
The cover part is designed as a simple flexible shell made of heat-resistant material that elastically surrounds the connector. This single-component design prevents flame discharge without requiring complex multi-part assemblies, thereby maintaining simplicity while improving safety.
Solution Approach 2:
The material properties of the cover part are changed to use heat-resistant materials (silicone or rubber) that can withstand high temperatures without deforming excessively. The material is selected to have appropriate elastic properties that allow it to seal the gap effectively while remaining simple in structure.
3Reliability
If the cover part is made of elastic material, then sealing performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The cover part is made from elastic heat-resistant materials (silicone or rubber) that can deform to accommodate variations in gap dimensions. This elasticity compensates for manufacturing tolerances in the connector and connector insertion portion, achieving reliable sealing without requiring extremely high manufacturing precision.
Solution Approach 2:
The flexible nature of the elastic material allows the cover part to conform to the actual geometry of the connector and connector insertion portion, sealing gaps effectively even when there are variations in manufacturing dimensions. The elastic deformation absorbs dimensional tolerances while maintaining sealing performance.
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
Prevents flame discharge from the connector, enhancing safety by blocking flames and maintaining control ability of the battery module.
Implementation Method 1
the cover part may be made of a material including a silicone or a rubber material
Data Source
AI summary
Proposed are a connector assembly and a battery module. The connector assembly may include a connector formed so that an external connector is inserted therein through a connector insertion portion formed in a casing, and a cover part coupled to the connector while surrounding an outer peripheral surface of the connector so as to seal a gap between the connector and the connector insertion portion. Accordingly, it is possible to block or delay discharge of a flame through the connector insertion portion of the battery module.