Battery Module Exposure Hole Cover for Thermal Runaway Isolation
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Solution Overview
Problem
Lithium secondary batteries used in large-capacity modules, such as those for electric vehicles, are prone to thermal runaway, fire, or explosion, where high-temperature fragments and flames from a failing cell can ignite adjacent cells, leading to chain reactions.
Innovation Solution
A battery module design featuring a connection plate with a cover portion protruding from exposure holes to block the movement of high-temperature materials, combined with a heat conduction pad and screen portions to manage ejected gases and fragments, maintaining venting functionality while preventing chain ignition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery cells are arranged in a large-capacity module, then energy density and power output are improved, but thermal runaway can propagate to adjacent cells causing chain reactions
Solution Approach 1:
The module case is segmented into multiple independent compartments, each housing a battery cell. The partition walls between compartments create physical isolation barriers that prevent thermal runaway propagation while maintaining electrical connectivity through the connection plate. This segmentation allows high-power density arrangement while containing harmful thermal effects within individual cell compartments.
Solution Approach 2:
The connection plate serves as an intermediary element that provides both electrical connectivity between cells and thermal isolation. The plate is designed with heat dissipation structures and thermal barriers that allow current flow while preventing heat transfer, thus mediating between the need for high power output and the need to prevent thermal runaway propagation.
2Ease of operation
If exposure holes are provided in the module case, then electrode terminals are accessible for electrical connection, but high-temperature fragments and flames can escape to ignite adjacent cells
Solution Approach 1:
Fireproof films or flexible heat-resistant barriers are installed at the exposure holes to block the ejection of high-temperature fragments and flames while allowing electrical terminals to pass through. These thin film barriers maintain terminal accessibility for electrical connection while preventing harmful material ejection that could ignite adjacent cells.
Solution Approach 2:
The module case and connection plate utilize composite materials that combine electrical conductivity with fire resistance. These composite structures allow electrical terminals to be accessible while inherently resisting fire propagation and fragment ejection, eliminating the need for separate protective measures at exposure holes.
3Reliability
If a barrier structure is added to prevent thermal propagation, then safety against fire is improved, but the complexity of the module structure increases
Solution Approach 1:
The connection plate is designed to serve multiple functions simultaneously: electrical connectivity between cells, structural support for the module, heat dissipation through integrated fins, and fire barrier through heat-resistant materials. This multi-functionality provides fire safety without adding separate barrier structures, thus avoiding increased complexity.
Solution Approach 2:
The partition walls and connection structures are merged into a single integrated module case design. The same structural elements that provide mechanical support and electrical connectivity also serve as fire barriers through their material selection and geometric configuration, combining multiple safety and functional requirements into a unified structure rather than adding separate components.
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 design effectively suppresses the spread of thermal runaway and explosions by containing high-temperature materials, enhancing safety and preventing secondary ignitions in adjacent cells.
Implementation Method 1
a cover portion configured to protrude toward the connection plate from an outer circumference of the exposure hole... capable of blocking the movement of high-temperature materials
Implementation Method 2
The battery module includes a heat conduction pad
Data Source
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AI summary
Disclosed is a battery module with improved stability against fire or explosion, and a battery pack and a vehicle including the same. The battery module includes a plurality of battery cells, each having electrode terminals respectively provided at an upper portion and a lower portion thereof; a connection plate having electric conductivity to electrically connect the plurality of battery cells, the connection plate including a body portion extending in a horizontal direction and a connection portion extending from the body portion to contact the electrode terminal; and a module case configured such that the connection plate is mounted to an outer side thereof, the module case being configured to accommodate the plurality of battery cells therein, the module case including a plurality of exposure holes configured to expose the electrode terminals of each of the plurality of battery cells to the outside and a cover portion configured to protrude toward the connection plate from an outer circumference of the exposure hole.