High-Voltage Thermal Fuse With Passive Battery Module Separation
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Solution Overview
Problem
Existing module connectors in electric vehicles lack cost-effectiveness and safety, particularly in preventing thermal runaway and explosions due to short circuits or unwanted chemical reactions within battery modules, which poses a risk to occupants.
Innovation Solution
A device with a connection module that passively opens the electrical and mechanical connection between battery modules and busbars when a trigger temperature is reached, utilizing a temperature-sensitive material or liquid in a container to trigger a safety mechanism, thereby interrupting heat transfer and preventing thermal chain reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a module connector is used to connect battery modules, then electrical and mechanical connection is established, but thermal runaway and explosions may occur due to short circuits or unwanted chemical reactions
Solution Approach 1:
A passive safety element is integrated into the connection module that preliminarily prepares a separation mechanism. When thermal runaway occurs, this pre-positioned mechanism automatically separates the connection elements, preventing thermal chain reactions. The safety feature is built-in from the design stage rather than added as an external protective measure.
Solution Approach 2:
The connection module serves as an intermediary component between battery modules or busbars. It includes a passive safety element that acts as a mediator to detect thermal conditions and facilitate safe separation. This intermediary structure isolates the harmful thermal effects from spreading between connected components while maintaining normal electrical connection during operation.
2Reliability
If active protection systems are used to prevent thermal runaway, then safety is improved, but system complexity and cost increase
Solution Approach 1:
The connection module employs a passive safety element that activates automatically based on thermal conditions without requiring external control systems, power supplies, or complex sensing electronics. The module serves itself by using the thermal energy from the battery modules to trigger the separation mechanism, eliminating the need for active monitoring and control systems.
Solution Approach 2:
The passive safety element is designed as a simple, cost-effective component that can be easily manufactured and integrated into the connection module. It functions as a single-use safety device that activates once during thermal runaway events, providing economical protection without requiring expensive active safety systems.
3Object-affected harmful factors
If the connection module passively opens upon reaching trigger temperature, then thermal chain reaction is prevented, but electrical connection is interrupted
Solution Approach 1:
The passive safety element extracts or removes the connection between the first and second connection elements when thermal runaway is detected. By taking out the thermal and electrical connection through automatic separation, the system prevents harmful thermal propagation while the electrical disconnection is an unavoidable consequence of the safety mechanism activation.
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 solution effectively delays thermal runaway and potential explosions, providing occupants with time to evacuate by passively opening the electrical and mechanical connection, ensuring safer operation of high-voltage systems without relying on external energy or control systems.
Implementation Method 1
utilizing a temperature-sensitive material or liquid in a container to trigger a safety mechanism
Implementation Method 2
temperature-sensitive material or liquid in a container to trigger a safety mechanism
Data Source
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AI summary
Device (10, 20, 50, 71, 80) for electrically and mechanically connecting battery modules (72, 73) in an energy storage device or two busbars between an energy storage device and another system, comprising: a first connecting element (11, 21, 54) with a first interface, wherein the first interface (12) is configured to be electrically and mechanically connected to a first battery module (72) in an energy storage device or a first busbar connected to an energy storage device; a second connecting element (13, 22, 55) with a second interface, wherein the second interface (14) is configured to be electrically and mechanically connected to a second battery module (73) in the energy storage device or a second busbar connected to another system;a connection module (15, 26), wherein the connection module (15, 26) is configured to provide an electrical and mechanical connection between a first connection area (24, 51) of the first connection element (11, 21, 54) and a second connection area (25, 53) of the second connection element (13, 22, 55); wherein the connection module (15, 26) is further configured to passively open the electrical and mechanical connection between the first connection area (24, 51) of the first connection element (11, 21, 54) and the second connection area (25, 53) of the second connection element (13, 22, 55) upon reaching a trigger temperature.