Battery Cell Vent Foam Barrier for Thermal Runaway Containment
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Solution Overview
Problem
Existing battery modules do not effectively prevent the spread of thermal runaway and propagation of heat between battery cells, which can lead to thermal runaway and propagation of heat, resulting in thermal runaway and fire, due to the lack of effective insulation and vent management.
Innovation Solution
A battery module with a protective member made of heat-insulating foam covering the vent of each cell, designed to prevent ignited materials from entering adjacent cells and blocking further thermal runaway by using a foam material with specific porosity and thickness to insulate and contain the thermal event.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are arranged closely to increase energy density, then productivity and space utilization are improved, but thermal runaway can spread between adjacent cells through vents
Solution Approach 1:
A protective member made of heat insulating material is positioned between adjacent battery cells, covering their vents. This intermediary structure prevents direct thermal contact and blocks the propagation path for thermal runaway while allowing the cells to maintain close arrangement for high energy density.
Solution Approach 2:
The protective member is specifically applied at the vent regions of battery cells where thermal runaway propagation is most likely to occur. This localized protection approach provides targeted thermal isolation exactly where needed, without requiring complete separation of all cell surfaces.
2Reliability
If vents are made larger to improve pressure relief, then safety during thermal events is improved, but ignited materials can more easily enter adjacent cells
Solution Approach 1:
The protective member is specifically positioned to cover the vent opening where ignited materials would escape, while the vent itself maintains its full size for effective pressure relief. The heat insulating material creates a localized barrier at the vent interface without restricting the vent's pressure release capability.
Solution Approach 2:
The protective member acts as an intermediary barrier that allows pressure to be relieved through the vent while simultaneously blocking the passage of ignited materials to adjacent cells. The heat insulating material provides selective permeability - allowing gas pressure through while preventing thermal and combustion material transfer.
3Object-affected harmful factors
If heat insulating material is added between battery cells, then thermal runaway propagation is prevented, but device complexity increases
Solution Approach 1:
The protective member is applied only at the vent regions of battery cells rather than between entire cell surfaces. This localized approach provides effective thermal isolation where thermal runaway propagation is most likely to occur, while minimizing the overall amount of additional material and structural complexity required.
Solution Approach 2:
The protective member uses a relatively simple heat insulating material structure that can be easily manufactured and integrated. The design accepts that this is a safety component that may need replacement in extreme cases, prioritizing effective thermal protection over long-term durability of the insulating material itself.
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 foam insulation effectively prevents the spread of thermal events between battery cells, reducing the risk of fire and ensuring safer operation by containing and isolating thermal runaway, thereby enhancing safety and reliability.
Implementation Method 1
a protective member made of a foam heat insulating material which covers a vent of a battery cell to prevent an igniting (or ignited) material generated in a battery cell experiencing an event (e.g., a thermal event) from entering a vent of another, adjacent battery cell, thus preventing further thermal runaway and propagation of heat
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
A battery module including: a plurality of battery cells arranged in one direction, each of the plurality of battery cells including a vent in an upper side thereof, the vent having a thin film shape; and a protective member covering an upper side of the vent of each of the plurality of battery cells. The protective member being made of a foam heat insulating material including a plurality of pores.