Battery Module Filling Structure for Thermal Runaway Venting
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Solution Overview
Problem
Existing lithium secondary batteries face issues with thermal runaway, leading to fire and explosion risks due to high-temperature gas discharge through various paths, and require separate insulating members that increase module size and complexity.
Innovation Solution
A battery module design that fills empty spaces with electrically insulating and fire-retardant materials, integrating a module case with an opening for assembly and using busbar assemblies to partition spaces for controlled gas discharge and eliminate separate insulating members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal barriers are provided between battery cells, then thermal propagation is blocked, but high-temperature water vapor discharges through various paths causing safety issues
Solution Approach 1:
A gas discharge guide structure is introduced as an intermediary component between the thermal barrier and the external environment. This guide structure channels high-temperature water vapor through a controlled path to a designated discharge port, preventing uncontrolled discharge while maintaining the thermal barrier's heat blocking function. The guide structure acts as a mediator that allows gas passage while preserving thermal isolation.
2Reliability
If separate insulating members are included for electrical insulation, then electrical safety is improved, but the size of the module case increases
Solution Approach 1:
The gas discharge guide structure is integrated directly into the module case as a built-in feature rather than a separate component. The guide structure forms an integral part of the case wall, eliminating the need for additional separate insulating members. This merging approach maintains electrical insulation functionality while avoiding increased module case size.
Solution Approach 2:
The integrated guide structure serves multiple functions simultaneously: it provides electrical insulation between conductive parts and the case, guides high-temperature gas discharge, and forms part of the case structure itself. This multi-functionality eliminates the need for separate dedicated insulating members.
3Reliability
If multiple separate components are used for thermal management and insulation, then functional requirements are met, but assembly complexity and manufacturing time increase
Solution Approach 1:
Multiple functions (thermal barrier, gas discharge guide, electrical insulation, and case structure) are merged into a single integrated module case design. The guide structure is formed as an integral part of the case rather than a separate component, reducing the total number of parts and simplifying assembly operations.
Solution Approach 2:
The integrated guide structure performs multiple functions simultaneously: thermal isolation, gas channeling, electrical insulation, and structural support. This multi-functionality reduces device complexity by eliminating the need for multiple specialized components.
4Temperature
If thermal barriers are added between cells, then heat conduction is controlled, but the number of parts increases requiring separate assembly steps
Solution Approach 1:
The thermal barrier function is merged into the integrated module case structure with the built-in gas discharge guide. The case itself serves as the thermal barrier while incorporating the gas channeling feature, eliminating the need for separate thermal barrier components and their assembly steps.
Solution Approach 2:
The gas discharge guide structure is pre-formed as an integral part of the module case during case manufacturing. This preliminary action eliminates the need for subsequent assembly steps to install separate thermal barriers and gas guide components, improving assembly speed.
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
Mitigates thermal propagation, directs high-temperature gas discharge, reduces module size, simplifies assembly, and enhances productivity by using electrically insulating and fire-retardant fillers.
Implementation Method 1
providing a thermal barrier between a plurality of battery cells. The thermal barrier is to block heat conduction to an adjacent cell
Implementation Method 2
since the filler is electrically insulated, it may replace a separate insulating member for electrical insulation inside the battery module
Data Source
AI summary
The present disclosure relates to a battery module, including a cell assembly including one or more battery cells and a busbar assembly electrically connecting the one or more battery cells, a module case including an opening part at least partially opened on one surface, and forming an accommodating space for accommodating the cell assembly therein through the opening part, a module cover coupled to the module case to close the opening part, and a filling part which is provided between an outside of the busbar assembly and the module case and includes an electrically insulating material, and an assembly method thereof.