Battery Module Lower-Frame Potting for Fire Containment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing battery module fixing structure is vulnerable to fire spread and rupture, particularly at the bottom of battery cells, due to inadequate glue filling, which compromises fire safety and fixation strength.

Innovation Solution

A battery module design featuring a module housing with a first frame covering the lower part of the battery cells and a second frame covering the upper part, where potting glue is filled in the internal area of the first frame, including a vent area, and ribs are used for enhanced fixation and heat management, with the glue being made of silicone material for flame retardancy and phase change materials for cooling performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If plastic is disposed around the upper and lower areas of the cells in the circumferential direction to provide structural support, then the mechanical strength is improved, but the glue cannot be properly filled on top and bottom of the cells, compromising fire safety

Engineering Contradiction:

Improvemechanical strengthVSAvoidfire safety

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent divides the fixing structure into two distinct components: an upper cell frame and a lower cell frame, each independently supporting the battery cells. This segmentation allows the lower frame to provide structural support while enabling proper glue filling in the gaps between cells, thus resolving the contradiction between mechanical strength and fire safety.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces potting glue as an intermediary material that fills the gaps between battery cells in the lower frame structure. This glue acts as a fire barrier while maintaining the mechanical support function, thus resolving the contradiction by adding a mediating element that addresses both requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If the existing fixing structure with upper and lower frames is used to support battery cells, then the structural stability is improved, but rupture occurs at the bottom of the cells during fire spread

Engineering Contradiction:

Improvestructural stabilityVSAvoidfire-induced rupture

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent applies potting glue beforehand in the lower frame structure to cushion and protect the battery cell bottoms from fire-induced rupture. This pre-applied protective layer prevents direct fire contact with the vulnerable cell bottoms, thus resolving the contradiction between structural stability and fire resistance.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent converts the vulnerable bottom area of battery cells, which is prone to rupture during fire, into a protected zone by filling it with fire-resistant potting glue. This transforms the harmful effect of fire exposure into a controlled environment where the glue acts as a protective barrier, thus resolving the contradiction.

Inventive Principle:

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

3Reliability

If potting glue is filled in the lower area of battery cells to prevent fire spread, then fire safety is improved, but the fixation strength may be compromised

Engineering Contradiction:

Improvefire safetyVSAvoidfixation strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent merges the fire protection function and fixation function into a single integrated lower frame structure with potting glue. The glue simultaneously provides fire barrier protection and mechanical fixation for the battery cells, thus resolving the contradiction by combining multiple functions into one solution.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent designs the lower frame structure with potting glue to serve multiple functions: fire barrier, mechanical support, and cell fixation. This multi-functional design resolves the contradiction by making the same structural element responsible for both fire safety and fixation strength.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 fire spread and enhances the fixation strength of battery cells by filling the potting glue in the lower area of the battery module, confining heat and pressure, thereby ensuring safety and improving cooling performance.

Implementation Method 1

confining heat and pressure, thereby ensuring safety

Methodology Applied

Scientific EffectHeat confinement: Thermal Insulation

Implementation Method 2

the glue being made of silicone material for flame retardancy and phase change materials for cooling performance

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS20240421413A1Battery module and battery pack and vehicle comprising the same

Publication Date: 2024.12.19 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a plurality of battery cells; a module housing accommodating the plurality of battery cells, the module housing including a first frame configured to cover a lower part of the battery cells and a second frame configured to cover an upper part of the battery cells; and a potting glue in at least a part of an internal area of the first frame.