Fire-Resistant Busbar Assembly for Battery Pack Insulation
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Solution Overview
Problem
Conventional busbars in battery packs lack sufficient fire resistance, leading to potential exposure and increased risk of short circuits and explosions due to melting under high temperatures, which can propagate flames outside the pack.
Innovation Solution
A busbar assembly comprising a glass fiber layer, a fire-resistant silicone layer, and a glass fiber tape, where the silicone layer is ceramified at high heat to maintain electrical insulation and the glass fiber tape provides structural rigidity, preventing the busbar from melting and maintaining insulation even in high-temperature environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional metal busbar is used for electrical connection in the battery pack, then excellent electrical conductivity is achieved, but fire resistance is insufficient and the busbar may melt under high temperature conditions
Solution Approach 1:
The patent applies composite materials by combining metal busbar with fire-resistant covering layers (silicone resin layer and glass fiber layer). This composite structure maintains the electrical conductivity of the metal busbar while adding fire resistance through the covering layers, preventing the busbar from melting under high temperature conditions and eliminating the technical contradiction between electrical conductivity and fire resistance.
2Power
If multiple battery modules are stacked to increase output, then high power is achieved, but heat accumulation occurs and temperature rises excessively
Solution Approach 1:
The patent applies beforehand cushioning by pre-installing fire-resistant covering layers on the busbar before high-temperature conditions occur. The silicone resin layer and glass fiber layer act as protective barriers that prevent direct contact between flames and the busbar, cushioning the thermal impact in advance. This allows the battery pack to achieve high power through multiple stacked modules while the fire-resistant covering prevents excessive temperature rise and heat accumulation.
3Reliability
If the busbar is surrounded by a covering member for insulation, then electrical insulation is improved, but the covering member may melt under high temperature and expose the busbar
Solution Approach 1:
The patent uses composite materials with a two-layer covering structure: an inner silicone resin layer providing electrical insulation and an outer glass fiber layer providing heat resistance. The silicone resin layer ensures electrical insulation properties, while the glass fiber layer withstands high temperatures without melting. This composite covering structure simultaneously improves both electrical insulation and heat resistance, preventing busbar exposure under high-temperature conditions.
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 assembly effectively maintains electrical insulation and structural integrity under fire conditions, preventing short circuits and explosions by ensuring the busbar does not melt or crack, thus enhancing safety in battery packs.
Implementation Method 1
the silicone layer is ceramified at high heat to maintain electrical insulation
Implementation Method 2
A busbar assembly comprising a glass fiber layer, a fire-resistant silicone layer, and a glass fiber tape
Data Source
AI summary
A busbar assembly according to an embodiment of the present disclosure includes: a busbar; a glass fiber layer covering the busbar; a fire resistant silicone layer covering the busbar and disposed in an empty space of the glass fiber layer; and a glass fiber tape covering the fire resistant silicone laver.