Battery Module Heat Blocking for Thermal Runaway Containment
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Solution Overview
Problem
Existing battery modules face challenges in preventing thermal runaway and heat propagation, which can lead to safety issues and reduced durability.
Innovation Solution
A battery module design that includes a cell assembly with multiple battery cells, a bus bar assembly, a plate portion, and at least one solid heat blocking member disposed to face the sealing portion and the bus bar assembly, effectively preventing thermal runaway and heat propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are assembled closely together to increase energy density, then productivity and space utilization are improved, but thermal runaway and heat propagation risks increase
Solution Approach 1:
The patent introduces heat blocking members as intermediary components positioned between adjacent battery cells. These members act as thermal barriers that prevent direct heat transfer while allowing the battery cells to maintain close proximity for high energy density. The heat blocking members are specifically placed in separation spaces formed by sealing portions of neighboring cells, creating a thermal buffer zone without compromising spatial efficiency.
Solution Approach 2:
The patent applies local quality by providing heat blocking members only in specific critical areas where thermal runaway propagation is most likely to occur. Rather than uniformly insulating all surfaces, the heat blocking members are strategically positioned at sealing portions and bus bar assemblies - the locations with highest thermal risk - thereby preventing heat propagation while maintaining overall energy density.
2Reliability
If heat blocking members are added to prevent thermal runaway, then safety is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent employs preliminary action by pre-forming heat blocking members with shapes that match the separation spaces in battery cells. The members are designed in advance with specific geometries (including inclined areas for easy insertion) and pre-positioning structures that align with sealing portions. This preliminary preparation enables straightforward assembly without requiring complex real-time adjustments or specialized assembly equipment.
Solution Approach 2:
The heat blocking members are designed with self-aligning features including inclined areas that guide automatic positioning during assembly. When inserted, the members automatically orient themselves to the correct position and orientation through the inclined surfaces, eliminating the need for precise manual alignment or complex positioning mechanisms. The members essentially assemble themselves once inserted into the separation space.
3Manufacturing precision
If solid heat blocking members are used instead of gel or foam, then manufacturing precision and reliability are improved, but ease of manufacture decreases
Solution Approach 1:
The patent applies parameter changes by transitioning from soft, deformable heat blocking materials (gel or foam) to rigid solid materials. This material parameter change provides several advantages: solid members maintain their predetermined shapes without deformation, ensure consistent positioning precision, and enable better thermal blocking performance. The rigid structure allows for precise manufacturing of heat blocking members with exact dimensions and geometries that match the separation spaces.
Solution Approach 2:
The solid heat blocking members are pre-manufactured with precise geometries and dimensions before assembly. Their rigid nature allows for high-precision manufacturing processes such as injection molding or CNC machining, ensuring that each member has exact dimensions that match the separation spaces. This preliminary precision manufacturing eliminates positioning errors that would occur with softer materials and simplifies the overall manufacturing process by allowing mass production of standardized 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 proposed solution significantly delays or prevents thermal runaway and heat propagation, thereby enhancing battery safety and durability while improving the convenience and efficiency of assembly work.
Implementation Method 1
at least one heat blocking member disposed to face the sealing portion and the bus bar assembly
Data Source
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AI summary
A battery module includes a cell assembly including a plurality of battery cells including a case containing an electrode assembly, a sealing portion formed by sealing the case, and an electrode lead exposed to an outside of the case, a bus bar assembly electrically connected to the electrode lead, a plate portion covering the cell assembly and the bus bar assembly, and at least one heat blocking member disposed to face the sealing portion and the bus bar assembly. The heat blocking member is solid.