Battery Module Protective Plates for Thermal Runaway Containment

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Solution Overview

Problem

Conventional batteries face challenges in ensuring safety and efficiency, particularly in high-voltage traction batteries, due to thermal runaway leading to thermal propagation and potential short circuits, which are often addressed with massive fire protection structures that increase weight and reduce energy density.

Innovation Solution

A battery design with separate compartments and non-load-bearing protective plates made of heat-resistant materials, such as steel or mica, positioned between cell modules to contain thermal ejections without increasing weight or space, using snap connections or attachments to cell modules and coolant lines for stability and heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If massive fire protection walls or struts are provided to improve safety, then safety is improved, but energy density is reduced and weight increases

Engineering Contradiction:

ImprovesafetyVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent uses thin protective plates made of heat-resistant material to provide fire protection between cell modules. These plates are much thinner and lighter than conventional massive fire protection walls, yet still effective at containing thermal runaways and preventing particle spread between modules.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If massive fire protection walls or struts are provided to improve safety, then safety is improved, but energy density is reduced

Engineering Contradiction:

ImprovesafetyVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The thin protective plates occupy minimal space between cell modules, preserving the energy density of the battery pack. The plates are sufficiently thin that they do not significantly reduce the volume available for active battery cells while still providing effective thermal containment.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The battery pack is divided into separate cell modules that are spatially separated and protected by the thin plates. This segmentation allows thermal runaways to be contained within individual modules without propagating to other modules, maintaining overall battery safety while maximizing energy density.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If cell modules are arranged adjacently to increase space efficiency, then space utilization is improved, but thermal propagation risk increases

Engineering Contradiction:

Improvespace utilizationVSAvoidthermal propagation risk

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

Thin protective plates are placed as intermediaries between adjacently arranged cell modules. These plates serve as barriers that prevent direct thermal and particle transfer between modules while allowing the modules to be positioned close together for efficient space utilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The battery pack is segmented into discrete cell modules with protective plates between them. This segmentation creates isolated thermal zones that can be arranged adjacently for space efficiency while preventing thermal propagation through the protective barriers.

Inventive Principle:

Principle #1Segmentation

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

Enhances safety by limiting thermal runaway consequences while maintaining energy density and reducing weight, allowing for efficient space utilization and simple assembly.

Implementation Method 1

The protective element is thermally resistant over a large part of its surface and has predetermined breaking points at the degassing points, which can be broken through by the material escaping from the respective battery cell in the event of a thermal fault.

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

The protective element is thermally resistant over a large part of its surface

Methodology Applied

Scientific EffectThermal resistance: Thermal Insulation

Implementation Method 3

using snap connections or attachments to cell modules and coolant lines for stability and heat dissipation

Methodology Applied

Scientific EffectHeat dissipation: Heat Sink

Data Source

PatentUS20260058282A1Battery With Particle Protection and Motor Vehicle Equipped Therewith

Publication Date: 2026.02.26 BAYERISCHE MOTOREN WERKE AG

AI summary

A battery and a motor vehicle equipped therewith has a battery housing in which several separate receiving compartments are formed by the housing walls of the housing and by load-bearing struts extending between the housing walls. Several cell modules are arranged in each of these receiving compartments. Between two cell modules arranged adjacently in one of the receiving compartments, a non-load-bearing protective plate is arranged in each case to contain, in regions, a spreading of a battery leakage from one of the adjacent cell modules to the other. This protective plate differs from the battery housing and from a structure of the receiving compartments.