Battery Module Cover Member for Thermal Runaway Venting Control

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Solution Overview

Problem

Conventional battery modules are vulnerable to thermal events, leading to potential thermal runaway and propagation, which can cause accidents such as fire or explosion, due to inadequate insulation and protection of electrode leads, and venting gas can escape through gaps in module terminals or connector terminals.

Innovation Solution

A battery module design featuring a cover member adhered to the side of the cell assembly where electrode leads protrude, filled between sealing portions of adjacent cells, and integrated with a venting unit to control the direction of flame and venting gas, preventing internal short circuits and thermal runaway propagation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional plastic insulating covers are used to secure insulation between electrode leads and module case, then insulation is provided, but the covers are vulnerable to flame and melt when exposed to thermal events

Engineering Contradiction:

Improveinsulation protectionVSAvoidflame vulnerability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter of the insulating cover from conventional plastic to heat-resistant material (such as ceramic or heat-resistant polymer), which maintains insulation properties while resisting flame and high temperature exposure during thermal events

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material structures where heat-resistant materials are combined with insulating properties to create covers that simultaneously provide electrical insulation and thermal resistance, preventing both insulation failure and flame vulnerability

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If electrode leads are positioned in wide terrace portions of battery cells, then connection is facilitated, but flame or venting gas can be intensively introduced to these areas causing thermal runaway propagation

Engineering Contradiction:

Improveconnection facilitationVSAvoidflame introduction risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent introduces protective covers as intermediary elements between the electrode leads and the harmful flame/venting gas environment. These covers act as barriers that prevent direct introduction of thermal events to the connection areas while maintaining electrical insulation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies preliminary protective measures by positioning insulating covers and protective structures around electrode leads before thermal events occur, preventing flame or venting gas from reaching critical connection areas and initiating thermal runaway propagation

Inventive Principle:

Principle #9Preliminary anti-action

3Ease of operation

If module terminals and connector terminals are located at electrode lead positions, then electrical connection is enabled, but gaps in these terminals allow venting gas to escape and cause thermal runaway between modules

Engineering Contradiction:

Improveelectrical connectionVSAvoidventing gas escape

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent employs nested protective structures where inner protective covers are placed within outer housing structures, creating multiple containment layers that prevent venting gas from escaping through terminal gaps while maintaining electrical connection functionality

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent introduces protective barriers as intermediaries between the internal battery components and the external environment, preventing venting gas from escaping through terminal gaps and propagating thermal runaway to adjacent modules

Inventive Principle:

Principle #24Intermediary (Mediator)

4Productivity

If battery cells are concentrated in narrow spaces to increase output and capacity, then energy density is improved, but vulnerability to thermal chain reaction increases

Engineering Contradiction:

Improveoutput and capacityVSAvoidthermal chain reaction risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent divides the battery module into segmented protective zones using insulating covers and protective barriers around each cell and electrode lead, creating firewalls that prevent thermal chain reactions even when cells are densely packed, thus maintaining high energy density while improving safety

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP4276997B1Battery module having improved safety

Publication Date: 2025.10.01 LG ENERGY SOLUTION LTD

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AI summary

The present disclosure discloses a battery module configured to improve safety when a thermal event occurs inside the battery module. A battery module according to one aspect of the present disclosure includes a cell assembly including a plurality of battery cells electrically connected to each other through an electrode lead; a module case accommodating the cell assembly in an internal space; and a cover member adhered to a side portion of the cell assembly in which the electrode lead protrudes in the internal space of the module case.