Dual-Layer Battery Module Cover for Thermal Runaway Containment

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Solution Overview

Problem

Existing battery modules are prone to thermal runaway, where heat generated by a battery cell exceeds the module's heat dissipation capacity, leading to undesirable temperature increases and deformation of the module cover, which can propagate thermal runaway to adjacent cells.

Innovation Solution

A battery module design featuring a dual-layer cover with an inner layer and an outer layer, where the inner layer has a higher coefficient of thermal expansion than the outer layer, allowing the cover to deform inwardly upon a thermal event, thereby inhibiting the propagation of thermal runaway.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single-layer cover is used to protect the battery module, then the structural simplicity is maintained, but the cover bows outward during thermal events increasing gaps and exposing adjacent cells to heat propagation

Engineering Contradiction:

Improvecover structureVSAvoidthermal runaway containment

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The cover is segmented into multiple layers (inner layer and outer layer) with different material properties. The inner layer is designed to deform inward during thermal events, while the outer layer maintains structural integrity, creating a segmented response to thermal stress that contains thermal runaway.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cover uses composite material construction with an inner layer made of a material having different thermal expansion properties than the outer layer. This composite structure enables the cover to exhibit controlled inward deformation during thermal events while maintaining overall structural strength and thermal containment capability.

Inventive Principle:

Principle #40Composite materials

2Strength

If the cover is rigidly fixed to prevent deformation, then structural integrity is maintained, but thermal expansion causes outward bowing that increases gaps and exposes cells to heat

Engineering Contradiction:

Improvecover structural integrityVSAvoidheat exposure to adjacent cells

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful thermal expansion effect into a beneficial inward deformation mechanism. The inner layer's thermal expansion, which would normally cause outward bowing, is harnessed to create controlled inward deformation that closes gaps and contains thermal runaway, transforming a harmful effect into a protective mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

Instead of preventing deformation to maintain structural integrity, the patent inverts the approach by designing the cover to deform inward during thermal events. This inverted deformation direction closes gaps between cells and thermal barriers, preventing heat exposure to adjacent cells while the outer layer maintains overall structural integrity.

Inventive Principle:

Principle #13The other way round (Inversion)

3Object-affected harmful factors

If gaps are reduced between cover and cells to prevent heat exposure, then thermal containment is improved, but thermal expansion causes outward bowing that increases these gaps

Engineering Contradiction:

Improveheat propagation to adjacent cellsVSAvoidthermal expansion of cover

Core Design Contradiction:

Object-affected harmful factorsVSTemperature

Solution Approach 1:

The patent converts the harmful thermal expansion effect into a beneficial inward deformation mechanism. The inner layer's thermal expansion, which would normally cause outward bowing, is harnessed to create controlled inward deformation that closes gaps between cells and thermal barriers, preventing heat exposure to adjacent cells.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 dual-layer cover design effectively contains thermal runaway by deforming inwardly, reducing the risk of heat propagation to adjacent cells and maintaining the structural integrity of the module cover.

Implementation Method 1

the inner layer has a higher coefficient of thermal expansion than the outer layer, allowing the cover to deform inwardly upon a thermal event

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20250141029A1Battery module having an inwardly deforming cover

Publication Date: 2025.05.01 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A battery module includes a container, a plurality of battery cells within the container, and a cover attached to sides of the container and extending in a plane over the plurality of battery cells wherein the cover comprises an inner layer and an outer layer. Upon a thermal event in one of the cells the battery cover can deflect inward toward the cells.