Battery Pack Upper Frame Layout for Thermal Propagation Control

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Solution Overview

Problem

Conventional battery packs are vulnerable to thermal events, with venting gas and flames propagating upward and potentially causing fires or explosions due to uncontrolled straight flows, especially in large battery packs used in vehicles.

Innovation Solution

A battery pack design featuring an upper frame with convex blocks and perforation holes that disrupt and disperse the flow of venting gas and flames, using convex and concave structures to create eddies and vortices, and a barrier to divide the internal space, enhancing structural stability and assembly efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple battery modules are densely arranged to increase output and capacity, then productivity and energy density are improved, but thermal safety deteriorates due to increased vulnerability to thermal propagation

Engineering Contradiction:

Improveoutput and capacityVSAvoidthermal safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The upper frame is segmented into multiple convex blocks that are distributed across the upper space of the battery pack. These convex blocks create separate flow paths and compartments, effectively segmenting the potential thermal propagation paths while maintaining the dense arrangement of battery modules below.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The convex blocks act as intermediary structures between the battery modules and the upper venting space. They intercept and redirect the upward flow of venting gas and flames, serving as a protective mediator that prevents direct thermal propagation to adjacent modules while allowing the dense packing configuration to be maintained.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-generated harmful factors

If the upper space is left open for venting, then thermal event relief is improved, but safety deteriorates due to uncontrolled straight flow of flame and venting gas

Engineering Contradiction:

Improveventing capabilityVSAvoidfire and explosion risk

Core Design Contradiction:

Object-generated harmful factorsVSObject-affected harmful factors

Solution Approach 1:

The convex blocks introduce curved and three-dimensional structures into the previously open upper space. These curved surfaces disrupt the linear upward flow of venting gas and flames, creating turbulent flow patterns that reduce the coherence and intensity of the thermal event propagation.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The convex blocks add vertical dimensionality to the venting space, transforming the two-dimensional open area into a three-dimensional structured environment. This dimensional addition creates multiple flow paths and reduces the straight-line velocity of venting gases, thereby diminishing their harmful effects while maintaining venting functionality.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If conventional simple structure is used, then ease of manufacture is improved, but safety deteriorates due to lack of thermal event control

Engineering Contradiction:

Improveassembly simplicityVSAvoidthermal event control

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The upper frame with convex blocks serves multiple functions simultaneously: it provides structural support for the battery modules, creates thermal barriers between modules, directs venting gas flow, and prevents flame propagation. This multi-functionality achieves enhanced safety without requiring additional separate components, thereby maintaining ease of manufacture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The safety features are merged into the upper frame structure itself rather than being separate components. The convex blocks are integrated directly into the frame, combining structural support and thermal protection functions into a single manufactured part, which simplifies the overall assembly process while providing comprehensive thermal event control.

Inventive Principle:

Principle #5Merging (Combining)

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 weakens and disperses the flow of venting gas and flames, preventing rapid propagation and enhancing the structural integrity and durability of the battery pack, thereby improving safety and stability.

Implementation Method 1

convex and concave structures to create eddies and vortices

Methodology Applied

Scientific EffectVortex: Vortex Ring

Implementation Method 2

disrupt and disperse the flow of venting gas and flames

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 3

a barrier to divide the internal space

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS20250329869A1Battery pack with enhanced safety

Publication Date: 2025.10.23 LG ENERGY SOLUTION LTD

AI summary

Disclosed is a battery pack with an improved structure to strengthen safety when a thermal event occurs. The battery pack includes a pack housing having an inner space; a plurality of battery modules provided in the inner space; and an upper frame having a plurality of convex blocks with a downward protruding shape at a lower portion thereof, the upper frame being coupled to an upper portion of the pack housing.