Battery Assembly Insertion Member for Thermal Runaway Venting

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Solution Overview

Problem

Lithium secondary battery assemblies face challenges in preventing the escape of high-temperature gases or flames during thermal runaway, which can lead to fires and explosions, and require improved heat and fire resistance while maintaining existing assembly processes.

Innovation Solution

Incorporating an insertion member with refractory particles and a binder that forms a three-dimensional shape, positioned between battery cells and a bus bar assembly, to mitigate heat and flame propagation, and venting gases in a controlled manner, while ensuring the insertion member is easily integrated into the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If empty spaces are left between battery cells for assembly flexibility, then ease of manufacture is improved, but fire propagation risk increases

Engineering Contradiction:

Improveassembly flexibilityVSAvoidfire propagation risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

A fire-resistant insertion member is placed in the empty space between battery cells and the accommodating case. This insertion member acts as an intermediary that blocks fire and high-temperature gas propagation while maintaining the empty space for assembly flexibility. The insertion member includes a fire-resistant core and a binder that melts at high temperature to allow gas venting.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insertion member is constructed as a composite material system combining a fire-resistant core (made of materials with high fire resistance) and a temperature-responsive binder. This composite structure provides both fire blocking capability and controlled gas venting function, resolving the contradiction between fire safety and assembly flexibility.

Inventive Principle:

Principle #40Composite materials

2Reliability

If fire-resistant materials are added to block flame propagation, then heat and fire resistance are improved, but device complexity increases

Engineering Contradiction:

Improveheat and fire resistanceVSAvoidassembly structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple functions are merged into a single insertion member: fire blocking, gas venting, and structural support. By combining these functions into one component rather than adding separate systems, the fire resistance is improved without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insertion member serves multiple purposes simultaneously: it blocks fire propagation, provides a controlled venting path for gases, and maintains the spatial relationship between battery cells and the accommodating case. This multi-functionality reduces the need for additional components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If a rigid fire barrier is used to prevent flame escape, then fire resistance is improved, but gas venting capability deteriorates

Engineering Contradiction:

Improvefire resistanceVSAvoidgas pressure buildup

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The binder material undergoes a phase transition from solid to liquid at a specific temperature (higher than normal operating temperature but lower than fire temperature). This phase transition creates openings in the insertion member structure, allowing high-temperature gases to vent while the fire-resistant core continues to block flame propagation.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The binder's melting temperature is specifically selected to change the structural parameters of the insertion member at different temperature conditions. At normal temperatures, the binder maintains structural integrity for fire blocking; at high temperatures, it melts to create venting pathways, thus resolving the contradiction between fire resistance and gas venting.

Inventive Principle:

Principle #35Parameter changes

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 solution effectively prevents or mitigates the escape of high-temperature gases and flames, enhances the stability and safety of battery assemblies by increasing heat and fire resistance, and facilitates the assembly process without significant changes to existing methods.

Implementation Method 1

a binder that binds the refractory particles to form a preset three-dimensional shape

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the binder may be melted at a preset temperature or higher

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

the insertion member may include refractory particles

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20240405327A1Battery assembly and assembling method of the same

Publication Date: 2024.12.05 SK ON CO LTD

AI summary

The present disclosure relates to a battery assembly including: a plurality of battery cells arranged in a preset stacking direction; an accommodating case accommodating the plurality of battery cells; an insertion space defined the plurality of battery cells and the accommodating case along the stacking direction; and an insertion member positioned in the insertion space, wherein the insertion member includes refractory particles; and a binder that binds the refractory particles to form a preset three-dimensional shape.