Laminated Battery Connector Header for Thermal Runaway Containment
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Solution Overview
Problem
Conventional battery modules fail to prevent the spread of high-temperature environments and high-pressure environments caused by flames or venting gas, which can lead to safety hazards and failure in thermal runaway tests.
Innovation Solution
A connector with a connector header body formed of a heterogeneous laminate material, including a heat-resistant metal with a melting point of 1000°C or higher and a lightweight metal, and a sealing gasket with a similar melting point, to maintain an airtight structure and prevent flame and gas diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional plastic injection connector is used, then the connector is lightweight and easy to manufacture, but it melts during high-temperature events and fails to prevent thermal runaway spread
Solution Approach 1:
The connector header body is constructed using a composite material comprising a heat-resistant resin matrix reinforced with inorganic filler particles. This composite structure provides both the required heat resistance (maintaining structural integrity at temperatures up to 150°C) and manufacturing feasibility through injection molding processes, resolving the contradiction between reliability and ease of manufacture
Solution Approach 2:
The invention changes the material parameters of the connector by selecting specific resins with glass transition temperatures above 100°C and inorganic fillers with high thermal stability. This parameter optimization enables the connector to withstand thermal runaway conditions while remaining manufacturable through conventional plastic injection processes
2Reliability
If the connector is designed to prevent high-temperature spread, then safety is improved, but the connector structure becomes more complex
Solution Approach 1:
The connector incorporates a heat-resistant sealing ring at the critical interface between the header body and battery module case. This localized application of heat-resistant materials (such as PTFE or silicone rubber with high thermal stability) provides the necessary safety function without requiring the entire connector structure to be redesigned, thus improving safety while minimizing structural complexity
Solution Approach 2:
The connector is divided into distinct functional components: a heat-resistant header body for structural integrity, a sealing ring for thermal isolation, and standard plastic housing for electrical connection functions. This segmentation allows each component to be optimized for its specific function while maintaining overall simplicity
3Reliability
If a heat-resistant metal connector is used, then thermal runaway prevention is improved, but the weight and cost increase significantly
Solution Approach 1:
The connector uses a composite material system combining organic heat-resistant resin with inorganic filler particles (such as glass beads, alumina, or silica). This composite provides thermal stability comparable to metal connectors (maintaining strength at elevated temperatures) while retaining the weight and cost advantages of plastic materials, effectively resolving the contradiction between thermal stability and weight
Solution Approach 2:
The invention employs conventional plastic injection molding processes to manufacture the heat-resistant connector, utilizing readily available heat-resistant resins and standard mold tools. This approach keeps manufacturing costs low and production time short, contrasting with expensive metal machining or specialized casting processes, while achieving sufficient thermal performance for safety requirements
Data Source
AI summary
A battery module includes a cell assembly including at least one battery cell, a module case in which the cell assembly is accommodated, and a connector mounted on the module case. The connector includes a connector terminal for electrical connection with the battery cell, a connector housing surrounding the connector terminal, and a connector header body coupled to the connector housing and mounted on the module case in such a manner that at least a part of the connector header body is inserted into the module case. The connector header body is formed of a heterogeneous laminate material including a heat-resistant metal material with a melting point of 1000° C. or higher and a lightweight metal material lighter than the heat-resistant metal material.