Battery Module Filling Structure for Thermal Runaway Isolation
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Solution Overview
Problem
Lithium secondary batteries face safety concerns due to thermal runaway issues, leading to fires and explosions, and existing solutions like thermal barriers and separate insulating members increase module size and complexity.
Innovation Solution
A battery module design that fills empty spaces with electrically insulating and fire-retardant materials, eliminating the need for separate insulating members and allowing for directed high-temperature gas discharge during fires, while reducing module size and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal barriers are added between battery cells, then thermal propagation is blocked, but high-temperature water vapor discharge is hindered and module size increases
Solution Approach 1:
The patent merges the thermal barrier function and electrical insulation function into a single integrated structure. The insulating member is positioned to simultaneously serve as a thermal barrier between battery cells and as an electrical insulator between the busbar assembly and module case, eliminating the need for separate components and reducing overall module size while maintaining thermal safety
Solution Approach 2:
The insulating member is designed to perform multiple functions: thermal insulation between adjacent battery cells, electrical insulation between the busbar assembly and module case, and structural support within the module. This multi-functional design reduces the number of components needed and optimizes space utilization
2Reliability
If separate insulating members are added for electrical insulation, then electrical safety is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines electrical insulation and thermal barrier functions into a single integrated insulating member structure, eliminating the need for separate insulating components and reducing assembly complexity
Solution Approach 2:
The insulating member is designed as a multi-functional component that simultaneously provides electrical insulation between the busbar assembly and module case, thermal barrier protection between battery cells, and structural support, thereby reducing the total number of parts required
3Reliability
If multiple separate components are used for thermal barrier and insulation, then safety functions are achieved, but assembly process complexity increases
Solution Approach 1:
The patent merges thermal barrier and electrical insulation functions into a single integrated insulating member that is pre-positioned within the module, eliminating the need for separate assembly steps for installing multiple safety components and simplifying the overall manufacturing process
4Ease of manufacture
If empty spaces are left in the module, then assembly is easier, but thermal propagation and gas discharge control are compromised
Solution Approach 1:
The insulating member acts as an intermediary component that fills the empty space between the busbar assembly and module case, providing both electrical insulation and thermal barrier functions while maintaining proper spacing and positioning of components within the module
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 mitigates thermal propagation, directs high-temperature gas discharge, reduces module size, simplifies assembly, and enhances safety by using electrically insulating and fire-retardant materials within the battery module.
Implementation Method 1
a filling part which is provided between an outside of the busbar assembly and the module case and comprises an electrically insulating material
Implementation Method 2
filling an empty space of a battery module by utilizing a filler comprising or made of a fire-retardant material
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The present disclosure relates to a battery module, including a cell assembly including one or more battery cells and a busbar assembly electrically connecting the one or more battery cells, a module case including an open part at least partially opened on one surface, and forming an accommodating space for accommodating the cell assembly therein through the open part, a module cover coupled to the module case to close the open part, and a filling part which is provided between an outside of the busbar assembly and the module case and includes an electrically insulating material, and an assembly method thereof.