Alternating Battery Module Venting to Block Thermal Runaway Spread

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Solution Overview

Problem

In electric or hybrid vehicles, battery packs face thermal runaway issues due to fire propagation between adjacent battery modules, leading to uncontrolled heat transfer and potential explosions.

Innovation Solution

A battery pack design featuring a tray assembly with alternating first and second battery modules, each with uniquely oriented outlets for venting gas and fireproof plates, along with a metal plate and thermal interface material for heat management, prevents flame propagation by misaligning module outlets and utilizing fireproof materials to contain and discharge venting gases effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery modules are arranged adjacently to maximize space utilization, then productivity and space efficiency are improved, but fire propagation between modules increases causing thermal runaway

Engineering Contradiction:

Improvespace utilizationVSAvoidfire propagation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The battery pack is divided into multiple independent battery modules, each with its own enclosure structure. The modules are arranged in a grid pattern with physical separations, creating segmented compartments that prevent fire from spreading between modules while maintaining high space utilization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Fireproof plates and heat dissipation structures are introduced as intermediary elements between adjacent battery modules. These intermediaries act as thermal barriers that block fire propagation paths while allowing the modules to remain closely arranged for space efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If module outlets are uniformly oriented for ease of manufacturing, then manufacturing precision is improved, but flame discharge efficiency decreases causing fire spread

Engineering Contradiction:

Improveoutlet orientation consistencyVSAvoidfire spread

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

Adjacent battery modules are designed with asymmetric outlet orientations. Specifically, modules alternate between having outlets facing upward and outlets facing outward, preventing direct alignment of discharge paths between neighboring modules. This asymmetric arrangement ensures that flames from one module cannot directly propagate to adjacent modules while maintaining manufacturability through standardized component designs.

Inventive Principle:

Principle #4Asymmetry

3Reliability

If heat dissipation structures are added to prevent thermal runaway, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvethermal runaway preventionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Thin fireproof plates and heat dissipation structures are integrated into the battery module enclosures. These thin-film elements provide effective thermal protection and fire resistance without significantly increasing the overall structural complexity or volume of the battery pack.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The fireproof plates and heat dissipation structures are merged with the existing module enclosure components rather than being added as separate external elements. This integration approach maintains structural simplicity while achieving reliable thermal runaway prevention.

Inventive Principle:

Principle #5Merging (Combining)

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

This design effectively delays heat transfer and prevents thermal runaway by rapidly discharging flames and venting gases outside the battery pack, reducing the risk of fire spread between modules and ensuring safer operation.

Implementation Method 1

module outlets for discharging venting gas from insides thereof

Methodology Applied

Scientific EffectGas venting: Pressure Gradient

Implementation Method 2

fireproof plates inserted between the stacked battery cells

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

thermal interface material for heat management

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

prevents flame propagation by misaligning module outlets

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS20250007067A1Battery pack for vehicle

Publication Date: 2025.01.02 HYUNDAI MOTOR CO LTD

AI summary

A battery pack for a vehicle, includes a tray assembly; a plurality of battery modules arranged to form a planar grid in the tray assembly; and a pack cover coupled to an upper side of the tray assembly, and together with the tray assembly, forming a pack internal space to accommodate the battery modules therein, in which the battery modules arranged in the tray assembly includes first battery modules of which module outlets for discharging venting gas from insides thereof are formed in a longitudinal direction of the battery pack, and second battery modules of which module outlets are formed in a transverse direction, and the first battery module and the second battery module are alternately disposed inside the tray assembly to form the planar grid.