Battery Module Water Injection With Air-Channel Sealing

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Solution Overview

Problem

Existing battery packs fail to effectively prevent the spread of thermal runaway phenomena by rapidly lowering temperature and extinguishing flames within affected battery modules, leading to potential ignition and explosion.

Innovation Solution

A battery pack structure featuring a water tank, coolant tubes, sensors, and a controller that introduces coolant into the affected module, coupled with expansion pads to block air channels and ensure coolant retention, thereby preventing flame spread.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a coolant is introduced into a battery module where thermal runaway has occurred, then the temperature inside the module is lowered quickly to prevent flame spread, but the coolant leaks through air channels without staying inside the module

Engineering Contradiction:

Improvetemperature inside battery moduleVSAvoidcoolant leakage

Core Design Contradiction:

TemperatureVSLoss of substance

Solution Approach 1:

The expansion pads are pre-installed in the air channels of the battery module housing, positioned to automatically expand and block the air channels when coolant enters the module. This preliminary placement of blocking elements prevents coolant leakage before the leakage problem occurs, allowing the coolant to remain inside the module for effective cooling.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The expansion pads act as an intermediary substance between the coolant and the air channels. When coolant enters the module, it triggers the expansion pads to expand, which then mediate by blocking the air channels and preventing coolant from leaking out, thus retaining the coolant inside for thermal management.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If air channels are left open for normal cooling, then air flow is maintained for heat dissipation, but coolant cannot be retained inside the module when thermal runaway occurs

Engineering Contradiction:

Improvecooling efficiencyVSAvoidcoolant retention

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The air channels are designed with dynamic expansion pads that can change their state based on conditions. During normal operation, the air channels remain open for efficient air cooling. When thermal runaway occurs and coolant enters the module, the expansion pads automatically expand to block the channels, dynamically adapting the cooling system to the emergency condition.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The physical state of the air channels is changed from open to blocked through the expansion of the pads when coolant is introduced. This parameter change allows the system to maintain open channels for normal cooling efficiency while enabling channel closure for coolant retention during thermal runaway events.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If the battery pack uses a simple air-cooled structure, then the device complexity is low, but the ability to respond to and contain thermal runaway events is insufficient

Engineering Contradiction:

Improvecooling system structureVSAvoidthermal runaway prevention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The cooling system is designed to be self-activating during thermal runaway events. When coolant is introduced into the module, it automatically triggers the expansion pads to expand and block the air channels without requiring external control systems or complex sensors. This self-service mechanism maintains simplicity while improving reliability.

Inventive Principle:

Principle #25Self-service

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 solution effectively prevents thermal runaway phenomena from spreading by quickly cooling affected modules and blocking air channels, reducing the risk of ignition and explosion.

Implementation Method 1

a coolant tube including a main tube connected to the water tank, a plurality of supply tubes configured to connect the main tube to each of the battery modules... configured to introduce a coolant into the battery module

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an expansion pad disposed inside each of the air inlet and the air outlet and configured to expand due to contact with the coolant introduced into the battery module to close the air inlet and the air outlet

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12412948B2Battery pack having structure allowing input of cooling water into battery module upon occurrence of thermal runaway phenomenon and ESS comprising same

Publication Date: 2025.09.09 LG ENERGY SOLUTION LTD

AI summary

A battery pack includes a pack housing; a plurality of battery modules; a water tank connected to the plurality of battery modules; a coolant tube including a main tube connected to the water tank, a plurality of supply tubes configured to connect the main tube and the battery modules to each other, and a bypass tube connected to the main tube at a point above a supply tube located at a top end among the plurality of supply tubes and at a point below a supply tube located at a bottom end; at least one sensor installed in the pack housing to detect a thermal runaway phenomenon generated in at least a part of the plurality of battery modules; and a controller configured to output a control signal for introducing a coolant into the battery module through the coolant tube when a thermal runaway phenomenon is detected by the sensor.