Battery Module Assembly Layout for Thermal Runaway Isolation
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Solution Overview
Problem
Existing battery modules with expandable designs face complications in electrical connection structures, leading to increased risk of internal short circuits during thermal runaway, which can cause rapid gas generation and explosion.
Innovation Solution
The battery module design includes separate electrical connections within each battery cell assembly, with electrode leads forming zigzag paths and using terminal busbars to connect adjacent assemblies, while avoiding direct connections between assemblies, and employing partitions to prevent heat propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cell assemblies are electrically connected to each other in existing expandable battery modules, then the electrical connection structure becomes complicated and internal short circuits occur during thermal runaway, but if they are not connected, then the electrical functionality and expandability are compromised
Solution Approach 1:
The battery module is divided into multiple battery cell assemblies (first and second assemblies) that are physically separated and independently managed. Each assembly contains battery cells that are electrically connected within the assembly but isolated from other assemblies by insulating structures, thereby preventing internal short circuits while maintaining electrical functionality through controlled connections at specific points.
Solution Approach 2:
An insulating structure is introduced as an intermediary element between the first and second battery cell assemblies. This insulating structure prevents direct electrical contact between assemblies during thermal runaway events, acting as a mediator that blocks harmful electrical pathways while allowing the module to maintain its expandable design and electrical functionality.
2Adaptability or versatility
If battery modules are stacked with electrically connected battery cell assemblies, then high voltage busbars are required to connect between assemblies, but this increases the number of high voltage components and potential failure points
Solution Approach 1:
The electrical connection system is segmented into isolated zones within each battery cell assembly, with controlled connection points. This segmentation allows battery modules to be stacked and connected in series or parallel configurations using fewer high voltage busbars, as the insulating structures already provide the necessary electrical isolation, reducing the total quantity of high voltage components required.
Solution Approach 2:
The insulating structure serves multiple functions: it provides electrical isolation between battery cell assemblies, enables thermal management spacing, and facilitates modular stacking configurations. This multi-functionality reduces the need for separate high voltage busbars for each connection, thereby reducing the total number of high voltage components while maintaining expandability.
Data Source
AI summary
A battery module includes a first battery cell assembly in which battery cells are stacked in the thickness direction of the battery cell, a second battery cell assembly in which each battery cell is stacked in a row in the longitudinal direction of the battery cell in the same number as the number of battery cells stacked in the first battery cell assembly, and a module case accommodating the first and second battery cell assembly. The battery cells of the first battery cell assembly are electrically connected to each other, and the battery cells of the second battery cell assembly are electrically connected to each other, but the battery cells are not electrically connected to each other between the first and second battery cell assemblies. Additionally, a battery pack includes the battery module.