Battery Module Insulation Layout for Thermal Runaway Blocking

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Solution Overview

Problem

Conventional battery modules face limitations in preventing fires and explosions due to uncontrolled heat and high-temperature particle diffusion between battery cells and bus bar plates, as existing heat insulation pads only partially block these hazards, allowing significant heat and particle transfer.

Innovation Solution

A battery module design incorporating a first heat insulator in the form of a silicon-based pad between individual battery cells and a second heat insulator made of a thermally expandable material, such as expanding paper, placed between electrode leads, which expands to block heat and high-temperature particles when a critical temperature is reached, effectively sealing the space between battery cells and the bus bar plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a heat insulation pad is disposed between adjacent battery cells, then heat and high-temperature particles are prevented from moving to adjacent cells, but an open space remains between the bus bar plate and battery cells allowing heat diffusion

Engineering Contradiction:

Improveheat and high-temperature particles diffusionVSAvoidfire and explosion prevention effect

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The heat insulation function is divided into two separate components: a first heat insulator (heat insulation pad) positioned between adjacent battery cells, and a second heat insulator positioned between the bus bar plate and battery cells. This segmentation allows each insulator to address specific heat diffusion paths independently, ensuring comprehensive coverage of all potential heat transfer routes while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second heat insulator acts as an intermediary component filling the open space between the bus bar plate and battery cells. This intermediary element blocks the heat diffusion path that would otherwise exist in the gap, preventing heat and high-temperature particles from traveling along this route while allowing the bus bar plate to maintain its electrical connection function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If heat insulation pads are added between battery cells, then fire and explosion risk is reduced, but the space between battery cells and bus bar plate is not utilized for cooling

Engineering Contradiction:

Improvefire and explosion preventionVSAvoidcooling performance

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The second heat insulator is designed with spatially varying properties: it provides thermal insulation where needed (between the bus bar plate and battery cells) while being positioned and dimensioned to allow air flow paths to remain open for cooling purposes. This local differentiation of insulation and cooling functions resolves the contradiction between fire prevention and thermal management.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The heat insulation system is designed to be dynamic in its functionality: during normal operation, the second heat insulator allows air circulation for cooling; during thermal events, it activates its insulation properties to block heat diffusion. This dynamic behavior enables the system to adapt to different operational conditions and resolve the contradiction between cooling and fire prevention.

Inventive Principle:

Principle #15Dynamics

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

This design significantly reduces the risk of fires and explosions by blocking heat and high-temperature particles, while maintaining cooling performance through the space between battery cells and the bus bar plate, which functions as an air passage at normal temperatures.

Implementation Method 1

a second heat insulator made of a thermally expandable material and placed between individual electrode leads, which expands to block heat and high-temperature particles when a critical temperature is reached

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

a first heat insulator of an heat insulation pad type disposed between individual battery cells

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250096366A1Battery module

Publication Date: 2025.03.20 LG ENERGY SOLUTION LTD

AI summary

There is disclosed a battery module including a first heat insulator formed in an insulation pad shape and disposed between battery cells; and a second heat insulator disposed between electrode leads and made of a material having a higher coefficient of thermal expansion than that of the first heat insulator, thereby blocking heat and high-temperature particles from moving between the respective battery cells and a bus bar plate and effectively reducing a risk of fires and explosions.