Expandable Battery Module Top Plate for Thermal Venting

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Solution Overview

Problem

Secondary batteries are vulnerable to thermal events, which can lead to uncontrolled gas and heat generation, potentially causing fires or explosions, especially in concentrated battery modules used in electric vehicles, posing risks to safety and property.

Innovation Solution

A battery module design with a top plate having higher expansibility than the base and side plates, featuring a venting hole and a module valve that opens at predetermined pressure or temperature, allowing controlled gas and heat management through expansion and delayed discharge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple battery cells are concentrated in a narrow space to increase output and capacity, then productivity and energy density are improved, but the risk of thermal events and fire propagation increases

Engineering Contradiction:

Improveoutput and capacityVSAvoidthermal event risk and fire propagation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent divides the battery module into multiple independent compartments using partition walls. Each compartment can contain one or more battery cells, and the partition walls prevent thermal propagation between compartments. This segmentation allows high-density cell arrangement while maintaining safety isolation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces cooling channels as intermediary structures between battery cells and compartments. These channels flow coolant to actively manage heat, serving as a thermal buffer that prevents heat accumulation and propagation. The cooling channels act as a mediator that dissipates thermal energy before it can cause harmful effects.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a venting hole is provided to allow gas discharge, then safety is improved by preventing explosion, but the structural integrity and sealing of the module case deteriorates

Engineering Contradiction:

Improvesafety against explosionVSAvoidstructural integrity and sealing

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent employs a movable cover that can slide or deform in response to internal pressure changes. Under normal conditions, the cover maintains a sealed state for structural integrity. When excessive pressure builds up during thermal events, the cover automatically moves to open the venting hole, providing dynamic safety response while preserving static sealing.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent uses a flexible or deformable cover material that can elastically deform under pressure. This flexible cover maintains structural integrity during normal operation but can yield to open venting channels when pressure exceeds safe thresholds, combining strength with safety functionality.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the top plate has higher expansibility to buffer thermal expansion, then safety is improved by reducing pressure buildup, but the structural stability and rigidity of the module case deteriorates

Engineering Contradiction:

Improvesafety against pressure buildupVSAvoidstructural stability and rigidity

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies different material properties to different parts of the module case. The top plate is designed with higher expansibility to accommodate thermal expansion, while the side plates and base maintain higher rigidity for structural support. This localized differentiation allows the top plate to safely buffer pressure without compromising overall structural stability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent may use composite material structures where the top plate combines materials with different thermal expansion coefficients. This allows the top plate to have controlled expansibility for safety while maintaining sufficient rigidity. The composite structure enables simultaneous optimization of both safety and structural properties.

Inventive Principle:

Principle #40Composite materials

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 buffers and manages thermal events by securing space for gas accumulation, reducing pressure, lowering temperature, and preventing chain reactions, thereby enhancing safety and reducing explosion risks.

Implementation Method 1

the top plate may have a lower elastic modulus or a higher thermal expansion coefficient compared to at least one of the base plate and the side plate

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

the module valve configured to be opened only when a temperature or pressure of the inner space exceeds a predetermined value

Methodology Applied

Scientific EffectPressure-induced valve opening: Pressure Increase

Data Source

PatentUS20250329862A1Battery module with reinforced safety

Publication Date: 2025.10.23 LG ENERGY SOLUTION LTD

AI summary

A battery module has an improved structure to improve safety. The battery module includes a cell assembly having at least one battery cell; and a module case configured to have a top plate, a base plate and a side plate to define an inner space and to accommodate the cell assembly in the inner space, the top plate being configured to at least partially have high expansibility compared to at least one of the base plate and the side plate.