Wire Harness Protection Bracket for Battery Module Vent Gas Shielding
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Solution Overview
Problem
Temperature/pressure sensing wire harnesses in battery modules are prone to loosening due to pulling forces and are susceptible to scorching from high-temperature gas ejected during thermal runaway, compromising safety and connection reliability.
Innovation Solution
A wiring harness protection bracket with a base plate and protective cover is designed to secure and protect the sensing wire harness, featuring a protective notch and fixing lug to prevent high-temperature gas from scorching and stabilize the connection, using a clamping structure to ensure reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire harness fixture is used to secure the temperature/pressure sensing wire harness on the upper portion of the battery module, then the wire harness is protected from pulling forces and loosening, but the sensing wires adjacent to the connector remain exposed to high-temperature gas from the explosion-proof valve
Solution Approach 1:
The protective cover is segmented with a protective notch that selectively shields the sensing wires adjacent to the connector while leaving other areas accessible. This segmentation allows the solution to address the specific vulnerability zone without compromising overall wire harness functionality or connection reliability.
Solution Approach 2:
The protective cover acts as an intermediary structure between the explosion-proof valve and the sensing wires. It physically intercepts and redirects high-temperature gas flow, preventing direct contact with the vulnerable sensing wires while allowing the wire harness fixture to continue securing the harness.
2Adaptability or versatility
If the sensing wires are individually connected to the connector in the section adjacent to the connector, then connection flexibility is improved, but the wires become difficult to bundle and more susceptible to scorching
Solution Approach 1:
The protective cover provides localized protection specifically to the vulnerable section of sensing wires adjacent to the connector. This local quality approach shields only the critical area exposed to high-temperature gas while maintaining the individual connection flexibility of the sensing wires throughout the rest of their length.
3Reliability
If the explosion-proof valve is oriented toward the upper portion of the battery module, then cell pressure relief functionality is maintained, but high-temperature gas easily reaches and scorchs the sensing wires adjacent to the connector
Solution Approach 1:
The protective cover serves as a mediating structure that intercepts the high-temperature gas flow path from the explosion-proof valve before it can reach the sensing wires. It redirects the gas flow in a safe direction while maintaining the explosion-proof valve's pressure relief orientation and functionality.
Solution Approach 2:
The protective cover provides preliminary protection by preemptively blocking the path of high-temperature gas before it can contact the sensing wires. This preventive measure is built into the structure design, ensuring protection is in place before any thermal runaway event occurs.
Data Source
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AI summary
A wiring harness protection bracket and a battery module are provided. The wiring harness protection bracket includes a base plate and a protective cover. The base plate is mounted to an end plate and a connector is disposed on the base plate. The protective cover is disposed on the base plate. An explosion-proof valve of a cell adjacent to the connector is defined as a first explosion-proof valve. The protective cover is located between the first explosion-proof valve and the connector. A sensing wire harness is disposed to bypass the protective cover and is connected to the connector.