Battery Module Venting Structure for Thermal Runaway Isolation

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Solution Overview

Problem

Rechargeable batteries, particularly lithium-ion cells, generate significant thermal energy that can lead to thermal runaway events, causing heat to spread between adjacent cells and affect the entire battery array.

Innovation Solution

A battery module design featuring insulating members with tapered portions and a vent feature that expels high-temperature gases from one cell into the external environment, minimizing gas transfer to neighboring cells and controlling thermal event propagation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery cells are placed in close proximity to maximize space utilization, then productivity and space efficiency are improved, but thermal runaway propagation risk increases due to heat transfer between adjacent cells

Engineering Contradiction:

Improvespace utilizationVSAvoidthermal runaway propagation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The battery module is segmented into isolated cell compartments using insulating members positioned between adjacent battery cells. This segmentation prevents thermal runaway propagation by creating physical and thermal barriers between cells, allowing close proximity placement while maintaining safety isolation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Insulating members serve as intermediary elements positioned between adjacent battery cells. These intermediaries provide thermal isolation and prevent direct heat transfer between cells, resolving the contradiction by enabling close spacing while blocking thermal runaway propagation paths.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If vent features are designed to expel high-temperature gases during thermal events, then thermal event control is improved, but device complexity increases due to additional safety components

Engineering Contradiction:

Improvethermal event controlVSAvoidsafety component complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The vent feature is merged with the battery module cover structure, integrating the safety function into an existing component rather than adding a separate complex system. The cover itself serves as both structural enclosure and thermal event management component, reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The battery module cover serves multiple functions: structural enclosure, thermal insulation, and active venting during thermal events. This multi-functionality eliminates the need for separate dedicated venting components, maintaining reliability while minimizing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 thermal runaway by directing and expelling high-temperature gases away from neighboring cells, preventing the spread of thermal events within the battery module.

Implementation Method 1

insulating members positioned on opposing sides of the first battery cell... insulating members include tapered portions disposed between the first battery cell and the vent feature, the tapered portions being configured to direct the high-temperature gases from the first battery cell away from the neighboring second battery cell

Methodology Applied

Scientific EffectPhysical containment and directional guidance: Physical Containment

Implementation Method 2

vent feature configured to expel high-temperature gases from the first battery cell into the external environment

Methodology Applied

Scientific EffectPressure-driven gas flow: Pressure Gradient

Implementation Method 3

insulating members positioned on opposing sides of the first battery cell... configured to direct the high-temperature gases away from the neighboring second battery cell

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250260121A1Thermal runaway mitigation battery module

Publication Date: 2025.08.14 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Embodiments include a battery module having a first battery cell, a neighboring second battery cell, and insulating members positioned on opposing sides of the first battery cell. The battery module also includes a battery module enclosure surrounded by an external environment and configured to house each of the first battery cell, the neighboring second battery cell, and the insulating members and a module cover mounted to the battery module enclosure and including a vent feature configured to expel high-temperature gases from the first battery cell into the external environment, to thereby minimize transfer of the high-temperature gases from the first battery cell to the neighboring second battery cell and control propagation of a thermal runaway event in the battery module. The insulating members include tapered portions disposed between the first battery cell and the vent feature.