Battery Module Flip Cover for Cell-to-Cell Flame Venting

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Solution Overview

Problem

Secondary battery cells generate heat during charging and discharging, leading to increased internal pressure and potential ignition, which can cause fires and explosions, and flames can easily spread between adjacent cells without proper protection.

Innovation Solution

A battery module design featuring a cover member with a fixed plate and flip portion that separates electrode tabs, using a heat-resistant material like polyphenylene sulfide reinforced with glass fibers, to prevent flame propagation and isolate spaces between electrode tabs, allowing internal gas and flame to be discharged externally.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If secondary battery cells are mounted in an energy storage system without cover members, then device complexity is reduced, but flame propagation between cells increases

Engineering Contradiction:

Improveflame propagationVSAvoidcover member structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The cover member is segmented into a fixed plate portion and a flip portion that can move independently. The flip portion is divided into multiple segments that can break away sequentially when exposed to flame or internal gas pressure, creating a progressive release mechanism that prevents complete closure while allowing controlled venting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flip portion transitions from a static closed state to a dynamic open state when exposed to flame or internal gas pressure. This dynamic behavior allows the cover member to adapt to emergency conditions by automatically opening to vent flames and gases while maintaining structural integrity during normal operation.

Inventive Principle:

Principle #15Dynamics

2Object-affected harmful factors

If the flip portion is designed to break easily, then flame venting is improved, but structural strength deteriorates

Engineering Contradiction:

Improveflame ventingVSAvoidflip portion strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The flip portion has different structural properties at different locations: the connection portion to the fixed plate is designed with lower strength to break easily under flame or gas pressure, while other portions maintain sufficient strength for normal operation. This localized weakness allows controlled failure at specific points to enable venting.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cover member is made from a composite material (polyphenylene sulfide reinforced with glass fibers) that provides high overall strength and heat resistance, while specific geometric features (thin sections, connection portions) are designed to fail at lower stresses to enable controlled breaking for flame venting.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If the flip portion remains closed, then flame isolation is improved, but internal pressure buildup increases

Engineering Contradiction:

Improveflame isolationVSAvoidinternal gas pressure

Core Design Contradiction:

Object-affected harmful factorsVSStress or pressure

Solution Approach 1:

The internal gas pressure and flame that would normally be harmful are converted into a useful function: they serve as the activating force to open the flip portion. The harmful pressure buildup is transformed into a beneficial venting mechanism that automatically releases pressure and flame when thresholds are exceeded.

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

Prevents ignition propagation and reduces flame spread between secondary battery cells, thereby preventing larger fires and chain explosions, especially in energy storage systems.

Implementation Method 1

the flip portion being pushed by internal gas or flame of the secondary battery cell discharged due to rupturing of the secondary battery cell

Methodology Applied

Scientific EffectGas pressure: Pressure Increase

Implementation Method 2

the flip portion being pushed by internal gas or flame of the secondary battery cell discharged due to rupturing of the secondary battery cell

Methodology Applied

Scientific EffectFlame: Combustion

Implementation Method 3

using a heat-resistant material like polyphenylene sulfide reinforced with glass fibers, to prevent flame propagation

Methodology Applied

Scientific EffectThermal resistance: Thermal Insulation

Data Source

PatentUS12355106B2Battery module comprising flip portion

Publication Date: 2025.07.08 SK ON CO LTD

AI summary

A battery module includes a cell support unit accommodating at least one or more secondary battery cells, a body frame member on which a plurality of the cell support units are installed, and a cover member disposed between adjacent cell support units. The cover member includes a fixed plate portion fixed between the adjacent cell support units, and a flip portion connected to the fixed plate portion and disposed between electrode tabs of the secondary battery cells adjacent to each other to separate a space between the electrode tabs externally, the flip portion being pushed by internal gas or flame of the secondary battery cells discharged due to rupturing of the secondary battery cells, to be position-moved so that the space between the electrode tabs communicate externally.