Battery Module Housing With Spark-Delay Plates for Safe Venting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Battery modules in energy storage systems and electric vehicles face safety issues due to uncontrolled venting of high-temperature gas and sparks, which can lead to fires and explosions, exacerbated by the introduction of external oxygen and potential short circuits between adjacent lithium secondary batteries.
Innovation Solution
A battery module design featuring a cell stack, module housing with spark delay protrusions and concave portions, a bus bar frame assembly with frame slits, and a fire-proof sheet assembly made of mica, which prevents high-temperature sparks and oxygen from escaping or entering, ensuring rapid venting and minimizing fire risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of lithium secondary batteries in a battery module is increased to satisfy output power characteristics and realize high capacity, then the power and capacity of the battery pack are improved, but the damage and safety risks increase when fire or explosion occurs
Solution Approach 1:
The battery module is divided into multiple battery cell compartments separated by insulating partitions. Each compartment can independently contain thermal events, preventing fire or explosion from spreading to other cells. This segmentation allows high capacity designs while limiting the scope of potential damage.
Solution Approach 2:
Heat-resistant insulating partitions made of ceramic or other fire-resistant materials are introduced as intermediaries between adjacent battery cells. These partitions act as barriers that block the transmission of heat, sparks, and flames, thereby protecting other cells from thermal runaway propagation while allowing the module to maintain high power output.
2Stress or pressure
If venting gas is rapidly discharged to the outside of the battery module to prevent internal pressure increase, then the internal pressure control is improved, but high-temperature sparks may be discharged along with the venting gas to cause fire
Solution Approach 1:
The harmful high-temperature sparks and electrode active materials are extracted and retained within the battery module through the spark retention structure, while only the venting gas is allowed to discharge externally. This separation eliminates the fire hazard of external sparks while maintaining pressure relief functionality.
Solution Approach 2:
The spark retention structure converts the harmful effect of high-temperature sparks into a beneficial containment mechanism. By designing the venting structure to redirect sparks inward or retain them within the module, the system transforms a potential fire hazard into a controlled thermal management feature that protects external components.
3Reliability
If a bus bar frame structure is used to prevent short circuit between lithium secondary batteries, then the electrical safety is improved, but oxygen may be easily introduced from the outside when the bus bar frame is damaged by spark and high-temperature gas
Solution Approach 1:
The module housing is constructed from composite materials that combine electrical insulation properties with fire resistance. This composite structure simultaneously provides short circuit prevention like a bus bar frame while also blocking oxygen ingress and resisting damage from high-temperature gases and sparks.
Solution Approach 2:
The module housing is designed to perform multiple functions: electrical insulation to prevent short circuits, structural support for battery cells, fire resistance to block oxygen and contain flames, and protection against mechanical damage. This multi-functional design eliminates the need for separate bus bar frame structures while providing comprehensive safety.
4Quantity of substance
If the number of battery modules in a battery pack is increased to realize high capacity, then the capacity of the battery pack is improved, but the damage and safety risks increase when fire or explosion occurs
Solution Approach 1:
The battery pack is segmented into multiple independent battery modules, each with its own fire containment barriers and thermal management system. This segmentation allows the pack to achieve high capacity through parallel configuration while limiting fire propagation to individual modules, thereby reducing overall damage risk.
Data Source
AI summary
A battery module includes a cell stack in which a plurality of battery cells are vertically stacked; a module housing including a base plate supporting the cell stack and a pair of side plates covering both side portions of the cell stack; and a bus bar frame assembly covering an opening portion formed on a side of the module housing in a longitudinal direction of the module housing, wherein each of the pair of side plates includes: a plurality of spark delay protrusions protruding from an inner surface of the side plate; and a plurality of spark delay concave portions recessed from the inner surface of the side plate.