Battery Module Sealing Structure for Thermal Runaway Containment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional battery modules face safety issues due to thermal runaway, fire, or explosion, where high-temperature gas or flame from one battery cell can ignite adjacent cells, leading to a chain reaction.

Innovation Solution

A battery module design featuring insulated covers with sealing filling members, accommodation spaces, and guide portions to contain and redirect high-temperature gas or flame, preventing propagation to adjacent cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery cells are arranged closely in a battery module to increase energy density, then productivity and space utilization are improved, but thermal runaway can spread to adjacent cells causing fire or explosion

Engineering Contradiction:

Improveenergy densityVSAvoidthermal runaway propagation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The battery module is divided into independent cell compartments separated by partition walls. Each partition wall includes a through-hole sealed with heat-resistant material, creating segmented barriers that prevent thermal runaway propagation while maintaining close cell arrangement for high energy density.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Heat-resistant sealing material is introduced as an intermediary substance in the through-holes of partition walls. This material blocks the transmission of high-temperature gas and flame between adjacent battery cells while allowing the partition structure to maintain structural integrity and electrical insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If partition walls are added between battery cells to prevent thermal runaway spread, then safety is improved, but device complexity increases

Engineering Contradiction:

ImprovesafetyVSAvoidmodule structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The partition wall structure serves multiple functions simultaneously: it provides electrical insulation between cells, creates physical barriers against thermal runaway propagation, and incorporates sealed through-holes for gas management. This multi-functionality reduces the need for additional separate safety components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The partition walls are strategically positioned and designed with localized through-holes only where needed for gas venting, rather than completely sealing all spaces. This localized approach provides safety where critical while maintaining manufacturing simplicity and avoiding unnecessary structural complexity.

Inventive Principle:

Principle #3Local quality

3Reliability

If exposing holes are sealed in covers to prevent fire spread, then safety is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvefire preventionVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heat-resistant sealing material is pre-installed in the exposing holes of the upper and lower covers before battery cells are assembled into the module. This preliminary action simplifies the overall manufacturing process by separating the sealing operation from the cell assembly operation, allowing each to be optimized independently.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sealing material used in exposing holes is designed as a simple, cost-effective component that can be easily replaced if needed. This approach prioritizes safety functionality while minimizing manufacturing cost and complexity, using straightforward sealing solutions rather than complex mechanical systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

Enhances safety by blocking and redirecting high-temperature gas or flame within the module, preventing thermal runaway and fires from spreading to adjacent cells.

Implementation Method 1

a filling member having electric insulation and filled in the plurality of exposing holes to seal the plurality of exposing holes

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP4148884B1Battery module, battery pack, and vehicle

Publication Date: 2026.03.18 LG ENERGY SOLUTION LTD

Figure 1
Figure 2
Figure 3

AI summary

Disclosed is a battery module, which includes a plurality of battery cells respectively having electrode terminals and configured to be erected long in an upper and lower direction, an upper cover having a plurality of exposing holes formed to expose the upper portion of each of the plurality of battery cells to the outside at least partially, a lower cover having a plurality of exposing holes formed to expose the lower portion of each of the plurality of battery cells to the outside at least partially, and a filling member having electric insulation and filled in the plurality of exposing holes to seal the plurality of exposing holes formed in at least one of the upper cover and the lower cover.