Battery Module Busbar Frame Blocking Thermal Runaway Venting

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Solution Overview

Problem

Battery modules in packs face challenges in suppressing the propagation of thermal runaway, leading to potential fires or explosions due to inadequate heat dissipation and the easy spread of high temperature gas and flame among stacked cells.

Innovation Solution

A battery module design featuring a busbar frame with a blocking member that expands to block the opening and prevent ejection of high temperature gas and flame, utilizing materials like foam or resin that can expand to contact the terminal busbar and edge of the opening, thereby containing pressure increases and preventing gas and flame propagation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a plurality of battery cells are stacked to form a battery module, then capacity and output are improved, but heat dissipation becomes difficult and thermal runaway propagation risk increases

Engineering Contradiction:

ImproveoutputVSAvoidheat dissipation

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The battery module is divided into multiple battery cell stacks, with each stack being a separate unit. The module frame includes multiple stacking spaces that can accommodate multiple stacks independently, allowing heat management and failure isolation at the stack level rather than requiring management of all cells as a single unit.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A cooling plate is introduced as an intermediary component between battery cells to facilitate heat dissipation. The cooling plate includes cooling channels that circulate coolant, acting as a thermal mediator to transfer heat away from the battery cells efficiently.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If battery modules are intensively disposed to increase vehicle mileage, then energy density is improved, but thermal runaway propagation to neighboring modules increases

Engineering Contradiction:

Improveenergy densityVSAvoidthermal runaway propagation

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The module frame is designed with separate stacking spaces for multiple battery cell stacks, creating physical segmentation between them. This segmentation allows intensive disposal of multiple stacks while maintaining spatial separation that can prevent thermal runaway propagation between adjacent stacks.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Fireproof columns are positioned between adjacent battery cell stacks as a beforehand protective measure. These columns act as fire barriers that prevent flame and hot gas from propagating from one stack to another, providing cushioning protection before thermal runaway can spread.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If end plates with openings are used to access terminal busbar, then electrical connection is improved, but ejection of high temperature gas and flame during thermal runaway increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidgas and flame ejection

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

Fireproof columns are positioned as intermediary barriers between the battery cell stacks and the exterior environment. These columns extend from the end plates into the stacking spaces, creating a physical barrier that prevents direct ejection of gas and flame through the openings in the end plates while still allowing electrical connection functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The fireproof columns are pre-positioned between the battery cells and the end plate openings as a beforehand protective barrier. When thermal runaway occurs, these columns are already in place to cushion and block the ejection path of high temperature gas and flame, preventing them from escaping directly through the terminal access openings.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 suppresses the ejection of high temperature gas and flame, reducing the risk of fire or explosion by utilizing the increased internal pressure to close the gap where gas and flame would typically escape, thereby preventing thermal runaway propagation to adjacent modules.

Implementation Method 1

a busbar frame (300) positioned between the battery cell stack (120) and the at least one end plate (400); and a terminal busbar (320) mounted on the busbar frame (300) and exposed through the opening (410H). The busbar frame (300) includes a blocking member (700) protruded toward the opening (410H)

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

Methodology Applied

Scientific EffectPressure absorption: Absorption (physical)

Data Source

PatentUS20240072375A1Battery module and battery pack including the same

Publication Date: 2024.02.29 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a battery cell stack where a plurality of battery cells are stacked; a module frame that accommodates the battery cell stack; end plates that are positioned at one side and the other side of the battery cell stack, and having openings; a busbar frame that is positioned between the battery cell stack and the end plate; and a terminal busbar that is mounted to the busbar frame, and exposed through the opening. The busbar frame includes a blocking member protruded toward the opening.