Battery Module Flame-Blocking End Frame for Thermal Runaway

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Solution Overview

Problem

Conventional battery modules are vulnerable to thermal runaway propagation, leading to potential fires or explosions due to inadequate flame blocking and venting gas management, especially with exposed terminals and connectors creating pathways for flame emission.

Innovation Solution

A battery module design featuring a blocking member with an air-permeable structure, potentially made of woven silica or glass fibers, positioned between the cell assembly and end frames to block flame movement while allowing venting gas to escape, thereby suppressing heat propagation and preventing external flame exposure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If module terminals and connectors are exposed to the outside for electrical connection, then electrical functionality is improved, but flame emission risk increases due to gaps and holes in the module frame

Engineering Contradiction:

Improveelectrical connection accessibilityVSAvoidflame emission risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an insulating member as an intermediary component that fills the space between the module terminal/connector and the module frame. This insulating member serves dual functions: maintaining electrical insulation while blocking flame propagation paths, thus resolving the contradiction between electrical accessibility and flame emission risk

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating member is designed with a porous structure that allows heat dissipation while maintaining flame blocking capability. The porous configuration enables thermal management without compromising the flame emission prevention function, addressing both electrical functionality and safety requirements

Inventive Principle:

Principle #31Porous materials

2Reliability

If insulating injection molding material is wrapped around module terminals to secure insulation distance, then electrical insulation is improved, but flame ejection passages are created when the material melts under thermal runaway conditions

Engineering Contradiction:

Improveelectrical insulationVSAvoidflame ejection passage

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the traditional insulating injection molding material with a heat-resistant insulating member that maintains its structural integrity under thermal runaway conditions. This heat-resistant material does not melt and form flame passages, thus eliminating the harmful effect while maintaining electrical insulation functionality

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The insulating member is constructed from heat-resistant composite materials that combine electrical insulation properties with high-temperature stability. This composite structure prevents material degradation under thermal stress, avoiding the creation of flame ejection passages while maintaining reliable electrical insulation

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If conventional module frames with holes for terminals are used, then manufacturing simplicity is maintained, but thermal runaway propagation to adjacent battery modules is enabled

Engineering Contradiction:

Improvemodule frame fabricationVSAvoidthermal runaway suppression

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent segments the module frame structure by introducing a separate insulating member component that fills the terminal area. This segmentation allows the frame to maintain its simple manufactured structure while the insulating member provides the flame blocking function, thus maintaining ease of manufacture while improving thermal runaway suppression

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating member acts as an intermediary element between the module frame and the external environment. It fills the gaps and holes necessary for terminal access while blocking flame propagation, thus preserving the simple frame structure while enhancing safety against thermal runaway propagation

Inventive Principle:

Principle #24Intermediary (Mediator)

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 prevents the propagation of thermal runaway and fire by blocking flames while allowing venting gases to be discharged, reducing the risk of external ignition and protecting adjacent components.

Implementation Method 1

a blocking member interposed between the end frame and the cell assembly and configured to block the movement of flame

Methodology Applied

Scientific EffectFlame blocking:

Implementation Method 2

a blocking member with an air-permeable structure, potentially made of woven silica or glass fibers

Methodology Applied

Scientific EffectGas permeation: Permeation

Data Source

PatentUS20240322348A1Battery module with reinforced safety

Publication Date: 2024.09.26 LG ENERGY SOLUTION LTD

AI summary

A battery module has a structure to improve safety. The battery module includes a cell assembly having at least one battery cell; a body frame configured to accommodate the cell assembly in an inner space and having an open portion formed in at least one side; an end frame coupled to the open portion of the body frame and having at least one of a terminal portion and a connector portion; and a blocking member interposed between the end frame and the cell assembly and configured to block the movement of flame.