Battery Module Flame Suppression Pad Sealing for Thermal Runaway

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery modules fail to prevent the propagation of flame, gas, or high-temperature particles from one battery cell to another, leading to thermal runaway and potential damage or danger in electric vehicles.

Innovation Solution

A battery module design featuring a flame suppression pad and a deformable close contact member made of a heat-resistant, elastic material that comes into close contact with the pad to block and direct flame, gas, or high-temperature particles, using a silicone-based material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a refractory pad is disposed between battery cells to prevent flame propagation, then safety is improved, but gaps may form between the module case and refractory pad due to processing errors, allowing flame and gas propagation

Engineering Contradiction:

ImprovesafetyVSAvoidcontact precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent uses a flexible seal member (elastomeric material) to fill gaps between the module case and refractory pad. This flexible film approach ensures continuous contact and prevents flame/gas propagation even when manufacturing tolerances create spacing issues, directly resolving the contradiction between safety reliability and manufacturing precision.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The seal member is pre-installed between the module case and refractory pad to anticipate and compensate for potential gaps caused by processing errors. This beforehand cushioning ensures that even if manufacturing precision varies, the flame propagation path is already blocked, maintaining safety reliability without requiring extremely tight manufacturing tolerances.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of manufacture

If the module case and refractory pad are not in close contact, then assembly is easier, but a gap is formed that allows flame or gas to propagate to neighboring battery cells

Engineering Contradiction:

Improveassembly easeVSAvoidflame propagation

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The seal member acts as an intermediary element between the module case and refractory pad. It mediates the connection, allowing the components to be assembled easily without requiring precise close contact, while simultaneously preventing flame and gas propagation through its sealing function. This resolves the contradiction between assembly ease and flame propagation prevention.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If flame suppression materials are added to prevent thermal runaway, then safety is improved, but the structural complexity of the battery module increases

Engineering Contradiction:

Improvethermal runaway preventionVSAvoidmodule structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the flame suppression function with existing structural components. The seal member integrates sealing and flame blocking functions, while the deformable close contact member combines structural support with flame suppression capabilities. This merging approach improves thermal runaway prevention without significantly increasing overall module structural complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The close contact member is designed with multi-functionality, serving both as a structural component maintaining battery cell spacing and as a flame suppression element. This universal design prevents thermal runaway while avoiding additional dedicated components, thus improving safety without proportionally increasing 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

Prevents flame and high-temperature particle propagation, allows controlled discharge in a preset direction, and prevents thermal runaway by blocking chain reactions.

Implementation Method 1

the close contact member may be made of a heat-resistant material with elasticity

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the close contact member may be formed to be deformable when coming into close contact with the flame suppression pad

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 3

a flame suppression pad disposed between the plurality of battery cells within the module case

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP4700957A1Battery module, and battery pack and vehicle including same

Publication Date: 2026.02.25 LG ENERGY SOLUTION LTD

Figure 1
Figure 2
Figure 3

AI summary

Disclosed is a battery module, and a battery pack and a vehicle including the same. The battery module includes a battery cell stack in which a plurality of battery cells are stacked; a module case in which the battery cell stack is accommodated; a flame suppression pad disposed between the plurality of battery cells within the module case; and a close contact member coupled to the module case and in close contact with the flame suppression pad.