Battery Module Flame Suppression Pad for Thermal Runaway Containment

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Solution Overview

Problem

Conventional battery modules fail to prevent the propagation of flame, gas, or high-temperature particles from one battery cell to another, leading to thermal runaway and potential damage or danger in electric vehicles.

Innovation Solution

A battery module design featuring a flame suppression pad with a cut portion that spreads to form two pad portions, coupled with direction-adjusting members, to block and direct flame, gas, or high-temperature particles away from neighboring cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a refractory pad is disposed between battery cells to prevent flame propagation, then safety is improved, but gaps form between the module case and refractory pad due to processing errors, allowing flame and gas to propagate to neighboring cells

Engineering Contradiction:

ImprovesafetyVSAvoidcontact between module case and refractory pad

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The refractory pad is designed to be movable rather than fixed, allowing it to dynamically adjust its position. When a battery cell expands or a gap appears, the pad can move to fill the gap and maintain contact with the module case, ensuring continuous flame blocking capability despite manufacturing tolerances or cell expansion.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The refractory pad's physical state is changed from rigid to flexible/movable, enabling it to adapt to varying gap sizes. This parameter change allows the pad to maintain effective contact with the module case under different conditions, preventing flame propagation while accommodating manufacturing variations.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If the refractory pad is made rigid to maintain structural stability, then structural integrity is improved, but it cannot adapt to battery cell expansion or gaps, reducing flame propagation prevention effectiveness

Engineering Contradiction:

Improvestructural integrityVSAvoidflame propagation prevention

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The refractory pad transitions from a static, rigid component to a dynamic, movable component that can adjust its position in response to battery cell expansion or gaps. This dynamic capability allows the pad to maintain both structural integrity and effective flame blocking by adapting to changing conditions within the battery module.

Inventive Principle:

Principle #15Dynamics

3Reliability

If flame blocking structures are added between battery cells, then thermal runaway prevention is improved, but the device complexity and number of components increase

Engineering Contradiction:

Improvethermal runaway preventionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The movable refractory pad serves multiple functions: it blocks flame propagation, adapts to battery cell expansion, maintains contact with the module case, and provides thermal insulation. By combining these functions into a single component, the design achieves effective thermal runaway prevention without significantly increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The refractory pad is designed as a flexible, thin fire-resistant barrier that can conform to the battery cell geometry and module case surface. This flexible film approach provides effective flame blocking with minimal added complexity compared to rigid structural solutions.

Inventive Principle:

Principle #30Flexible shells and thin films

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

Prevents flame and high-temperature particle propagation, allowing controlled discharge in a preset direction and preventing thermal runaway.

Implementation Method 1

a flame suppression pad disposed between the plurality of battery cells within the module case

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The flame suppression pad may be made of a heat-resistant material

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentEP4683087A1Battery module, and battery pack and vehicle including same

Publication Date: 2026.01.21 LG ENERGY SOLUTION LTD

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AI summary

Disclosed is a battery module, and a battery pack and a vehicle including the same. The battery module includes a battery cell stack in which a plurality of battery cells are stacked; a module case in which the battery cell stack is accommodated; and a flame suppression pad disposed between the plurality of battery cells within the module case, wherein a cut portion is formed at one end of the flame suppression pad.