Battery Module Case Venting for Thermal Runaway Pressure Relief

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Solution Overview

Problem

Existing battery modules are prone to rapid pressure buildup and thermal runaway during thermal events, leading to potential explosion due to ineffective heat dissipation and pressure relief.

Innovation Solution

A battery module design featuring a module case with weld bead portions and pressure relief portions that allow gas to vent through gaps, combined with a rib fitting system for enhanced assembly and a gas venting hole configuration for directional gas discharge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the module case is completely sealed to protect battery cells, then protection against external contaminants is improved, but pressure relief capability deteriorates leading to potential explosion

Engineering Contradiction:

Improveprotection against external contaminantsVSAvoidinternal pressure buildup

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The module case is designed with differentiated local properties: most areas are hermetically sealed for protection, while specific localized regions (pressure relief portions) have gaps without weld beads to allow pressure release. This resolves the contradiction by providing both sealing and venting functions in different locations of the same structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The potential harmful effect of pressure buildup is converted into a beneficial pressure relief mechanism. By intentionally designing gaps at specific locations, the case transforms the dangerous pressure accumulation into a controlled pressure release system that prevents explosion while maintaining overall sealing.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Power

If multiple battery cells are connected to increase capacity and output, then energy requirements are met, but thermal runaway spread risk increases

Engineering Contradiction:

Improveoutput and capacityVSAvoidthermal runaway resistance

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The module case is segmented into multiple pressure relief portions distributed at different locations. This segmentation allows localized pressure management, preventing uniform pressure buildup that could propagate thermal runaway across all cells. Each gap serves as an independent pressure relief zone.

Inventive Principle:

Principle #1Segmentation

3Strength

If the module case uses complete welding for structural integrity, then mechanical strength is improved, but pressure relief capability deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidpressure relief function

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The welding strategy is differentiated by location: weld beads are applied at most edge lines for structural integrity, while specific edge lines intentionally omit weld beads to create pressure relief portions. This local differentiation resolves the contradiction between strength and pressure relief.

Inventive Principle:

Principle #3Local quality

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

Effectively disperses and relieves internal pressure during thermal events, preventing rapid pressure rise and potential explosion by allowing controlled gas release through multiple venting points.

Implementation Method 1

at least one pressure relief portion having a gap at the edge line where the first plate and the second plate are not welded

Methodology Applied

Scientific EffectPressure relief through gaps: Pressure Gradient

Implementation Method 2

weld bead portions where a first plate and a second plate are welded on an edge line where the first plate and the second plate meet each other

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20260031476A1Battery module and battery pack including same

Publication Date: 2026.01.29 LG ENERGY SOLUTION LTD

AI summary

A battery module includes at least one battery cell; and a module case having an inner space accommodating the battery cell, and the module case includes: weld bead portions where one plate and another plate are welded on an edge line where they meet each other, and a pressure relief portion having a gap between the plates that are not welded.