Battery Module Insulation Structure for Thermal Runaway Mitigation

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Solution Overview

Problem

Existing battery modules and packs lack effective insulation and cooling mechanisms, particularly for secondary batteries used in vehicles, which can lead to safety issues due to heat propagation and potential thermal runaway.

Innovation Solution

A battery module design featuring insulating members with extension portions and busbar holders that enhance insulation and cooling, using materials like mica and composite materials to prevent heat propagation and protect vulnerable vents, along with a housing structure to accommodate these modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If battery cells are arranged closely to increase capacity, then energy density is improved, but heat propagation risk increases

Engineering Contradiction:

Improvebattery cell capacityVSAvoidheat propagation

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent introduces insulating members as intermediary elements positioned between adjacent battery cells. These insulating members include extension portions that extend toward the cap plate, creating a physical barrier that interrupts heat propagation pathways while allowing the battery cells to remain closely arranged for high capacity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating members extend in the vertical dimension (toward the cap plate) rather than only in the horizontal plane between cells. This three-dimensional insulation approach blocks heat propagation in multiple directions without sacrificing the horizontal compactness needed for high energy density.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If insulating members are added between battery cells to prevent heat propagation, then safety is improved, but device complexity increases

Engineering Contradiction:

Improvethermal safetyVSAvoidbattery module structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating members are merged with the existing battery module structure by positioning them in the spaces between adjacent battery cells. The extension portions of the insulating members integrate with the cap plate area, combining insulation functionality with the structural framework rather than adding separate complex systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating members serve multiple functions: they provide thermal insulation between cells, maintain structural spacing between adjacent cells, and protect the cap plate area. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If extension portions of insulating members reach the cap plate to protect vents, then thermal protection is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvevent exposure to heatVSAvoidinsulating member positioning

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The insulating members have different structural characteristics in different regions: the main body provides general insulation, while the extension portions specifically target the cap plate and vent areas. This local differentiation allows the extension portions to reach the cap plate for enhanced protection without requiring the entire insulating member to be precisely positioned, thereby reducing overall manufacturing precision requirements.

Inventive Principle:

Principle #3Local quality

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

The design effectively mitigates heat propagation and protects battery cells from thermal events, enhancing safety and capacity in battery packs, particularly for vehicle applications.

Implementation Method 1

first insulating members each of which is between a pair of adjacent battery cells and has an upwardly extending extension portion

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250300276A1Battery module and battery pack including the same

Publication Date: 2025.09.25 SAMSUNG SDI CO LTD

AI summary

A battery module includes battery cells arranged in one direction, first insulating members each of which is between a pair of adjacent battery cells and has an upwardly extending extension portion, a second insulating member above the battery cells, the second insulating member being configured to allow the extension portion to extend therethrough and be exposed therefrom, a pair of end plates at opposite ends of the battery cells in the one direction, and a pair of side plates along the battery cells in the one direction and coupled to the end plates. Due to the insulating members, propagation of heat to neighboring battery cells may be prevented or at least mitigated even if the distance between the neighboring cells is reduced. Consequently, it is possible to increase the capacity and energy density of each of the battery cells.