Battery Pack Module Isolation for Thermal Runaway Containment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery packs face structural damage and potential explosion due to unwanted flow of flames and conductive particles during thermal runaway, leading to short circuits and additional fires.

Innovation Solution

A battery pack design incorporating protective covers and reinforcing frames that separate and insulate battery modules, with bus bars mounted on these covers to prevent direct contact and include gas flow paths for venting, using materials with high heat resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If battery modules are connected in series or parallel to achieve high capacity, then the energy density and power output increase, but the risk of thermal runaway spreading and structural damage increases

Engineering Contradiction:

Improveenergy densityVSAvoidsafety against thermal runaway spread

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The battery pack is divided into multiple independent battery modules, each surrounded by protective covers and positioned in separate subspaces defined by reinforcing frames. This segmentation isolates thermal runaway events to individual modules, preventing spread to other modules while maintaining high overall capacity through series/parallel connection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Protective covers made of heat-resistant materials are introduced as intermediary elements between adjacent battery modules. These covers act as thermal barriers that intercept and block the propagation of flames and conductive particles during thermal runaway, allowing high energy density configurations without compromising safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If bus bars are directly connected to battery module terminals, then the electrical connection is simple and efficient, but the risk of short circuits from conductive particles and flames increases

Engineering Contradiction:

Improvebus bar connection simplicityVSAvoidshort circuit risk from conductive particles

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

Protective covers are positioned between the bus bars and battery module terminals, serving as intermediary barriers that block conductive particles and flames while allowing electrical connection. This maintains manufacturing simplicity by not requiring complex connection mechanisms while eliminating short circuit risks.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective covers function as thin film barriers that provide electrical isolation and thermal protection between conductive components (bus bars) and battery modules. These covers maintain the simplicity of direct connection while adding a protective layer against harmful factors.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If reinforcing frames are added to partition the accommodating space, then the structural integrity and thermal isolation improve, but the device complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidnumber of reinforcing components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The reinforcing frames serve multiple functions simultaneously: they provide structural support to maintain pack integrity, partition the accommodating space into subspaces for thermal isolation, and support the protective covers. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving enhanced strength and isolation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If protective covers are used to block flame and particle spread, then the safety against thermal runaway spread improves, but the manufacturing process complexity increases

Engineering Contradiction:

Improveprotection against thermal runawayVSAvoidnumber of protective components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective covers are integrated with the bus bar assembly, combining the electrical connection function and the thermal protection function into a single unified component. This merging reduces the total number of separate parts and simplifies the assembly process, thereby limiting the increase in device complexity while maintaining effective protection against thermal runaway.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12537252B2Battery pack

Publication Date: 2026.01.27 SK ON CO LTD

AI summary

A battery pack includes a plurality of battery modules, a battery pack case engaged to hold the plurality of battery modules and structured to provide an accommodating space in which the plurality of battery modules are accommodated, wherein the battery pack case includes one or more reinforcing frames structured to partition the accommodating space into subspaces in which the plurality of battery modules are held, one or more protective covers respectively coupled to the one or more reinforcing frames to cover part of each battery module and part of each reinforcing frame, and one or more bus bars coupled to the one or more protective covers and structured to electrically connect the plurality of battery modules.