Battery Module Flame-Retardant Pad Layout for Thermal Runaway

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Solution Overview

Problem

In battery modules, thermal runaway can lead to chain combustion reactions due to heat transfer between adjacent cells, posing safety risks and performance degradation.

Innovation Solution

Incorporating flame-retardant pads, such as silicone foam pads with inorganic refractory fillers and extinguishing agents, between battery cells to delay or block heat and flame transfer, ensuring the pads' area is equal to or larger than the electrode assembly's, and strategically positioning them to avoid electrode leads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery cells are stacked closely to achieve high integration and lightweight structure, then manufacturing efficiency and energy density improve, but heat transfer between cells increases leading to thermal runaway propagation

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidheat transfer

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

A flame-retardant pad is introduced as an intermediary component between adjacent battery cells. This pad serves as a thermal barrier that blocks heat transfer pathways while maintaining the compact stacked structure. The pad material specifically targets and interrupts the heat conduction path that would otherwise propagate thermal runaway between cells, thus resolving the contradiction between close stacking and heat isolation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The flame-retardant pad utilizes composite material construction combining flame-retardant properties with thermal insulation characteristics. This composite approach enables the pad to simultaneously provide structural support, thermal barrier function, and flame retardancy, allowing close cell stacking while preventing heat propagation through the use of specially engineered composite materials.

Inventive Principle:

Principle #40Composite materials

2Reliability

If flame-retardant pads are added between battery cells to block heat transfer, then thermal safety improves, but device complexity and manufacturing steps increase

Engineering Contradiction:

Improvethermal safetyVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flame-retardant pad is designed to perform multiple functions simultaneously: thermal insulation, flame retardancy, and mechanical cushioning between cells. By consolidating these protective functions into a single component, the design adds thermal safety without proportionally increasing structural complexity, as the pad integrates multiple safety functions rather than requiring separate components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If flame-retardant pads are positioned to cover the entire electrode assembly area for maximum thermal protection, then heat blockage effectiveness improves, but pressure distribution uniformity and cell performance may deteriorate

Engineering Contradiction:

Improveheat blockage effectivenessVSAvoidpressure distribution uniformity

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The flame-retardant pad employs local quality differentiation by varying its material properties or thickness in different regions. Areas with higher thermal risk receive enhanced flame-retardant coverage, while other regions maintain optimized pressure distribution characteristics. This localized approach ensures heat blockage effectiveness where most needed while preserving overall pressure uniformity and cell performance.

Inventive Principle:

Principle #3Local quality

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

This solution effectively suppresses chain combustion reactions, improving safety by delaying heat transfer and preventing damage to battery cells, while maintaining performance by controlling swelling and preventing non-uniform pressure.

Implementation Method 1

at least one flame-retardant pad interposed between at least one pair of adjacent battery cells among the plurality of battery cells or between the battery cell stack and the housing

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The flame-retardant pad may include a silicone foam pad

Methodology Applied

Scientific EffectHeat absorption: Heat Sink

Data Source

PatentUS20230327254A1Battery module and battery pack including the same

Publication Date: 2023.10.12 LG ENERGY SOLUTION LTD

AI summary

A battery module including: a battery cell stack including a plurality of battery cells, each of the battery cells including an electrode assembly, are stacked; a housing accommodating the battery cell stack; and at least one flame-retardant pad interposed between at least one pair of adjacent battery cells among the plurality of battery cells or between the battery cell stack and the housing, in which an area of the flame-retardant pad is equal to or larger than an area of the electrode assembly.