Battery Module Reinforcement Beam for Rigidity and Thermal Isolation

Solution Overview

Problem

Large-sized battery modules face issues with mechanical rigidity and thermal runaway propagation due to increased width, leading to deformation and enhanced risk of secondary accidents.

Innovation Solution

A battery module structure incorporating a structural reinforcement beam between unit stacks, fixedly coupled to the module housing, enhances mechanical rigidity and prevents thermal runaway propagation by using a rigid material with flame retardants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the width of the module housing is increased to accommodate more battery cells, then the energy density and space efficiency are improved, but the mechanical rigidity deteriorates and deformation occurs more easily

Engineering Contradiction:

Improvenumber of battery cellsVSAvoidmechanical rigidity

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The battery module is divided into multiple unit stacks, each independently accommodated within the module housing. This segmentation allows the overall structure to maintain rigidity while accommodating a larger quantity of battery cells, as each unit stack can be individually supported and isolated

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A support structure is introduced as an intermediary element between the battery cells and the module housing. This support structure provides additional mechanical reinforcement to the widened module housing, preventing deformation while maintaining the increased width necessary for accommodating more battery cells

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If the width of the module housing is increased to accommodate more battery cells, then the energy density and space efficiency are improved, but the module housing deforms more easily under load, vibration or impact

Engineering Contradiction:

Improvenumber of battery cellsVSAvoidstructural stability

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The battery module is divided into multiple unit stacks, each independently accommodated within the module housing. This segmentation allows the overall structure to maintain rigidity while accommodating a larger quantity of battery cells, as each unit stack can be individually supported and isolated

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A support structure is introduced as an intermediary element between the battery cells and the module housing. This support structure provides additional mechanical reinforcement to the widened module housing, preventing deformation while maintaining the increased width necessary for accommodating more battery cells

Inventive Principle:

Principle #24Intermediary (Mediator)

3Quantity of substance

If battery cells are densely packed to increase energy density, then the space efficiency is improved, but the risk of thermal runaway propagation increases

Engineering Contradiction:

Improvenumber of battery cellsVSAvoidthermal runaway propagation

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The battery module is divided into multiple unit stacks that are spatially separated within the housing. This segmentation creates natural barriers that can limit the propagation of thermal runaway, while still maintaining high density through efficient arrangement of the segmented units

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structure serves as a physical intermediary between adjacent battery unit stacks. This intermediary element creates spacing and barriers that can inhibit the direct propagation of thermal runaway between densely packed battery cells, while still allowing high overall density

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4175035B1Large-sized battery module and battery pack including same

Publication Date: 2025.10.08 LG ENERGY SOLUTION LTD

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AI summary

Provided is a battery module including: a cell stack structure including a plurality of unit stacks each including stacked battery cells; a module housing accommodating the cell stack structure; and a structural reinforcement beam arranged in parallel with the battery cells and arranged between adjacent unit stacks, wherein upper and lower end portions of the structural reinforcement beam are respectively partially inserted into and fixedly coupled to an upper surface and a lower surface of the module housing such that the unit stacks are spatially spaced apart from each other.