Battery Module Housing With Flame and Cooling Passages
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Solution Overview
Problem
Secondary battery cells in energy storage systems can ignite and cause fires, leading to the spread of flames between cells due to the lack of a cover member to prevent flame propagation, posing a risk of explosion and degradation of battery performance.
Innovation Solution
An energy storage system design that includes a housing with a first cover to oppose the electrode tab side, a second cover to oppose the opposite side, a flame passage between the covers, and a cooling passage separated from the flame passage, along with a blocking member to prevent flame spread, and protrusions between battery modules to create a second cooling passage for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If secondary battery cells are mounted in an energy storage system without a cover member to prevent flame spread, then the structure is simple and easy to manufacture, but the flame can easily spread from one cell to adjacent cells causing explosion and performance degradation
Solution Approach 1:
The housing is divided into multiple covers (first cover, second cover, third cover) that are selectively disposed around the module stack. Each cover acts as an independent flame barrier, segmenting the potential flame propagation path between battery cells while maintaining manufacturing simplicity through modular assembly
Solution Approach 2:
The first cover is positioned between the electrode tab and the module stack, acting as an intermediary component that specifically blocks flame spread toward the electrode tab while allowing normal operation. This intermediary structure prevents direct flame contact with critical components
2Reliability
If a first cover is added to oppose the electrode tab side to prevent flame spread, then flame propagation is blocked, but the device complexity increases
Solution Approach 1:
The housing structure integrates multiple functions into the cover members: the first cover prevents flame spread to electrode tabs, the second and third covers provide additional flame barriers on opposite sides, and collectively they form a unified protective housing. Each cover serves both as a structural element and a fire safety component
Solution Approach 2:
The first, second, and third covers are nested around the module stack in a coordinated arrangement, with each cover positioned to address specific flame propagation risks. The covers work together as an integrated protective system, with the first cover nested between the electrode tab and module stack, and the second and third covers positioned on opposite sides
3Temperature
If cooling passages are formed between the covers and module stack, then heat dissipation is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The cooling passages are integrated into the housing structure itself, merging the cooling function with the protective cover members. The passages are formed as voids within the housing material or as channels in the cover members, combining structural support and thermal management in a single component rather than adding separate cooling systems
Solution Approach 2:
The housing structure with integrated cooling passages provides self-service thermal management by dissipating heat directly from the module stack through the covers. The passages enable natural or forced convection cooling without requiring external cooling components, allowing the housing to serve both protective and thermal management functions
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 and external flame spread from secondary battery cells, reducing the risk of explosion and maintaining battery performance by directing flames and heat away from adjacent cells through separate passages and cooling mechanisms.
Implementation Method 1
a cooling passage is formed between the second cover and the module stack
Implementation Method 2
a flame passage is formed between the first cover and the module stack
Implementation Method 3
a blocking member disposed in the flame passage and passing gas and blocking flame
Data Source
AI summary
An energy storage system includes a battery module including a plurality of secondary battery cells and an electrode tab disposed on one or both sides; and a housing accommodating a module stack in which the plurality of battery modules are stacked, wherein the housing includes a first cover disposed to oppose at least one side surface of the module stack on which the electrode tab is disposed, and a second cover disposed to oppose at least one of the side surfaces of the module stack on which the electrode tab is not disposed, and wherein a flame passage is formed between the first cover and the module stack, and a cooling passage is formed between the second cover and the module stack.