Battery Module Insulating Cover With Venting Guide
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Solution Overview
Problem
In lithium secondary battery packs, thermal runaway in one battery cell can lead to serial ignition of adjacent cells and modules, causing widespread fires due to uncontrolled emission of flame and gas.
Innovation Solution
A battery module design featuring an insulating cover with a venting guide to direct flame and gas emissions away from the cells, combined with a heat-resistant sheet between the insulating cover and bus-bar assembly, and an outer cover with venting holes to manage and contain emissions, preventing foreign material intrusion and minimizing risk of serial ignition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are bundled to form a battery pack for high energy applications, then energy capacity is improved, but thermal runaway propagation risk increases
Solution Approach 1:
The battery pack is divided into multiple battery modules, each module containing a specific number of battery cells arranged in series. This segmentation isolates thermal runaway events to individual modules, preventing propagation to the entire battery pack while maintaining high energy capacity through the aggregation of multiple modules.
Solution Approach 2:
Heat-resistant sheets are positioned between adjacent battery modules to act as thermal barriers. These intermediary materials prevent heat transfer and flame propagation between modules during thermal runaway events, while allowing the battery pack to maintain high energy density through optimized module arrangement.
2Ease of operation
If flame and gas emissions are uncontrolled during thermal runaway, then immediate venting is achieved, but serial ignition of adjacent cells occurs
Solution Approach 1:
Heat-resistant sheets are selectively positioned at specific locations between battery modules, particularly at areas where thermal runaway emissions are most likely to propagate. This localized protection strategy enables effective containment of harmful emissions while maintaining overall venting efficiency through designated escape paths.
Solution Approach 2:
Heat-resistant sheets are pre-installed between battery modules before thermal runaway events occur. This preliminary protective measure ensures that when thermal runaway happens, the emissions are immediately contained by the pre-positioned barriers, preventing serial ignition before it can propagate to adjacent cells.
3Reliability
If insulating cover is disposed to face bus-bar assembly for protection, then electrical safety is improved, but flame emission control becomes challenging
Solution Approach 1:
The insulating cover is designed with differentiated properties: the portion facing the bus-bar assembly provides electrical insulation and protection, while other portions incorporate flame-resistant materials or structural features that guide and contain flame emissions. This localized quality differentiation simultaneously achieves electrical safety and flame emission control.
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 directs and contains flame and gas emissions from a failing battery cell, reducing the risk of thermal runaway propagation and enhancing safety by ensuring controlled release of hazardous materials, thereby minimizing the risk of serial ignition and improving overall safety of the battery module and pack.
Implementation Method 1
thermal runaway of a battery cell in a battery module leads to thermal runaway of another battery cell or another battery module
Implementation Method 2
configured to emit flame or gas occurring in one or more of the plurality of battery cells
Implementation Method 3
a heat-resistant sheet disposed between the insulating cover and the bus-bar assembly
Implementation Method 4
the partition wall forming a first flow path guiding the flame or gas emitted from the venting guide
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A battery module includes: a plurality of battery cells; and an insulating cover disposed on one side of the plurality of battery cells, the insulating cover comprising a venting guide configured to emit flame or gas occurring in one or more of the plurality of battery cells.