Battery Module Flame Separation Structure for Thermal Runaway Containment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional battery modules lack effective flame separation and dissipation mechanisms, risking the propagation of heat and flames between adjacent battery cells, which can lead to increased explosion risks and reduced safety.

Innovation Solution

Incorporating a flame separation structure with a first extension portion between the battery cell stack and the module frame, and a second extension portion corresponding to electrode leads, along with a flame-retardant pad and sheet, to create an isolated space for blocking and dissipating flames externally, while using partition walls and vent holes for enhanced safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery cells are stacked closely to improve space utilization and capacity, then productivity and energy density are improved, but heat and flame propagation between adjacent cells increases safety risks

Engineering Contradiction:

Improvebattery capacityVSAvoidheat and flame propagation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces flame separation structures that divide the battery module into isolated compartments. These structures include flame separation sheets positioned between adjacent battery cells and extension portions that reach toward the module frame, creating segmented zones that prevent flame and heat propagation while maintaining close cell spacing for high capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flame separation structure acts as an intermediary barrier between battery cells. The flame separation sheet and extension portions create a physical and thermal barrier that mediates heat transfer, allowing the cells to remain closely spaced while preventing direct flame propagation and heat transfer between adjacent cells.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If flame separation structures are added between battery cells to prevent flame propagation, then safety is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

ImprovesafetyVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs thin flame separation sheets as the primary safety barrier. These flexible thin films are positioned between battery cells and can be easily installed without adding significant structural complexity. The thin film approach provides effective flame separation while maintaining simplicity in the overall module design.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flame separation structure includes extension portions that extend in the vertical direction toward the module frame, creating a three-dimensional barrier system. This dimensional approach allows the flame separation to occur at multiple levels (between cells and toward the frame) without significantly increasing horizontal complexity or manufacturing difficulty.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If extension portions are extended toward the module frame to block flame propagation paths, then flame blocking capability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveflame blocking capabilityVSAvoidpositioning precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The extension portions of the flame separation structure are designed to self-align and attach to the module frame without requiring high-precision positioning. The structure utilizes the existing module frame geometry for attachment, allowing the extension portions to naturally position themselves during assembly, thereby reducing manufacturing precision requirements while maintaining effective flame blocking capability.

Inventive Principle:

Principle #25Self-service

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 blocks flame transmission between battery cells and facilitates easy discharge of flames and heat to the outside, enhancing safety by preventing accumulation and promoting rapid dissipation, thereby reducing the risk of thermal runaway and explosion.

Implementation Method 1

at least one flame separation structure interposed between the adjacent battery cells among the plurality of battery cells, or between the battery cell stack and the module frame

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

flame is easily discharged to the outside, enhancing safety by preventing accumulation and promoting rapid dissipation

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 3

facilitates easy discharge of flames and heat to the outside

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20230275300A1Battery module and battery pack including the same

Publication Date: 2023.08.31 LG ENERGY SOLUTION LTD

AI summary

A battery module includes a battery cell stack including a plurality of battery cells. The battery module also includes a module frame accommodating the battery cell stack. The battery module also includes a flame separation structure between two adjacent battery cells of the plurality of battery cells, or between the battery cell stack and the module frame. The flame separation structure includes a first extension portion extending into a first space between the battery cell stack and the module frame.