Battery Module Flame Path Layout for Thermal Propagation Control
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Solution Overview
Problem
Conventional battery modules are prone to thermal damage of neighboring cells due to uncontrolled flame paths during internal ignition, leading to potential chain ignition or explosion.
Innovation Solution
The battery module design modifies the flame path by relocating the bus-bar terminal exposure from the end cover to the upper side of the case body and bending the bus-bar terminal to protrude above the case body, guided by a protrusion accommodation portion and a fitting member to direct flames centrally within the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the bus-bar terminal is exposed through the end cover opening, then electrical connection is facilitated, but flame and heat can escape directly causing thermal damage to neighboring battery modules
Solution Approach 1:
The bus-bar terminal is repositioned from a horizontal exposure through the end cover to a vertical exposure through the upper surface of the case body. This dimensional change redirects the flame path from a horizontal trajectory that would directly affect neighboring modules to a vertical trajectory that escapes upward, thereby eliminating direct thermal damage to adjacent battery modules while preserving electrical connection functionality
2Object-affected harmful factors
If the bus-bar terminal is bent to protrude above the case body, then flame path is redirected centrally, but structural complexity increases
Solution Approach 1:
The bus-bar terminal is designed to serve multiple functions: it provides electrical connection, acts as a structural support element, and functions as a flame path guide. By integrating these functions into a single component with a bent configuration, the design achieves flame path control without adding separate structural elements, thereby managing complexity while achieving the desired safety outcome
3Ease of operation
If multiple battery modules are disposed adjacent to each other with terminals adjacent for convenient connection, then ease of connection is improved, but thermal propagation risk increases
Solution Approach 1:
The flame escape path is extracted from the horizontal plane where it would directly impact neighboring modules to the vertical dimension. By removing the horizontal flame propagation pathway through the end cover opening and replacing it with vertical escape through the upper surface, the design maintains close module spacing for connection convenience while eliminating the thermal propagation route that would cause chain ignition
Data Source
AI summary
A battery module includes a cell stack accommodated inside a case body having at least one open side and including a plurality of battery cells stacked and disposed in one direction; a bus-bar frame assembly including a bus-bar frame disposed at the front or rear of the cell stack, and a plurality of bus-bars mounted to the bus-bar frame and electrically connected to electrode leads of the battery cells; and an end cover coupled to the open end of the case body so as to cover the bus-bar frame assembly. The plurality of bus-bars may include a bus-bar terminal having an upper end exposed to the outside at least to be higher than the upper surface of the case body and configured to function as a module terminal. The end cover may be configured such that the upper end of the bus-bar terminal is partially exposed therethrough.