Battery Module Connector Assembly for Thermal Runaway Venting

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Solution Overview

Problem

Conventional battery modules are vulnerable to fire due to the exposure of plastic connectors, which can melt and spread flames to adjacent modules during thermal runaway, leading to uncontrolled gas and flame discharge.

Innovation Solution

A battery module design featuring a metal flame retardant block with a ceramic coating surrounding the connector housing, along with a sealing gasket and fixing plate, to prevent gas leakage and direct high-temperature gases through a controlled venting path, enhancing flame retardancy and minimizing the risk of ignition to neighboring modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a plastic connector is used for electrical connection, then ease of manufacture is improved, but flame retardancy deteriorates causing fire propagation risk

Engineering Contradiction:

Improveconnector manufacturingVSAvoidflame retardancy

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The connector assembly combines plastic housing (for ease of manufacture and electrical insulation) with a metal flame retardant block (for fire resistance). This composite structure integrates materials with complementary properties to simultaneously achieve manufacturability and flame retardancy.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The metal flame retardant block acts as an intermediary protective element between the plastic connector and the high-temperature environment. It serves as a thermal barrier that prevents direct heat exposure to the plastic connector, thereby maintaining connector integrity during thermal events.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the connector is exposed to the outside for electrical connection, then ease of operation is improved, but gas leakage risk worsens during thermal runaway

Engineering Contradiction:

Improveelectrical connectionVSAvoidgas discharge

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The flame retardant block is strategically positioned only at the portion of the connector exposed to the outside environment through the module case. This localized protection approach provides flame retardancy where it is most needed (at the external exposure point) while maintaining electrical connectivity functionality.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The connector assembly is segmented into distinct functional components: the plastic housing for electrical connection, the metal flame retardant block for protection, and the sealing gasket for gas containment. This segmentation allows each component to optimize its specific function while working together as an integrated system.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If conventional plastic connector material is used, then manufacturing cost is reduced, but heat resistance deteriorates leading to connector melting

Engineering Contradiction:

Improveconnector material costVSAvoidheat resistance

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The solution uses a composite structure combining inexpensive plastic material for the connector housing with a metal flame retardant block. This allows the majority of the connector (the housing) to use cost-effective plastic while the critical heat-exposed portions use heat-resistant metal, optimizing both cost and thermal performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Heat-resistant metal material is applied locally only to the flame retardant block portion that interfaces with high-temperature environments, rather than making the entire connector from expensive heat-resistant material. This localized application maintains cost effectiveness while providing necessary thermal protection.

Inventive Principle:

Principle #3Local quality

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 connector loss and delays ignition, preventing gas leakage and directing high-temperature gases through a safe path, thereby minimizing the risk of fire propagation to adjacent modules.

Implementation Method 1

a coating layer of an incombustible material on a lower surface facing the inside of the module case

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

discharging the gas through a pre-intended safety path

Methodology Applied

Scientific EffectGas flow direction control:

Data Source

PatentUS20240421398A1Battery module to which connector having improved flame retardancy is applied

Publication Date: 2024.12.19 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a cell assembly having battery cells; a module case accommodating the cell assembly and having a connector mounting hole at one side and a connector assembly connected to a circuit board provided inside the module case and having at least a portion exposed to the outside of the module case through the connector mounting hole. The connector assembly includes a connector housing having connector pins inside and having at least a portion exposed to the outside of the connector mounting hole and a flame retardant block formed of a metal material and surrounding the circumference of the connector housing inside the module case. The flame retardant block has a coating layer of an incombustible material on the surface facing the inside of the module case.