Battery Module Venting Channel for Thermal Runaway Gas Routing
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Solution Overview
Problem
Lithium ion batteries and other batteries face issues with gas buildup and thermal runaway due to the complexity of power modules containing numerous plastic parts, which can lead to defects and combustible materials during manufacturing and thermal events.
Innovation Solution
A battery module with a venting channel made of metal, featuring aligned venting apertures to direct excess gas away from sensitive components, secured by tabs or fasteners, and incorporating wiring apertures for routing, with insulating coatings and gaskets for improved sealing and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If numerous plastic parts are used to mechanically fix the cell stack and hold components, then the battery module can be assembled with various functional components, but the manufacturing complexity increases and defects may accumulate
Solution Approach 1:
The patent merges multiple functions into the battery module housing itself: the housing provides mechanical support for the cell stack, contains integrated vents for gas expulsion, and incorporates mounting structures for electronic components. This consolidation eliminates the need for numerous separate plastic parts, reducing manufacturing complexity while maintaining all necessary functions.
Solution Approach 2:
The battery module housing is designed as a multi-functional component that simultaneously serves as structural support, gas venting system, and mounting framework. This universal design allows a single component to perform multiple roles that previously required separate parts, simplifying the overall assembly.
2Adaptability or versatility
If numerous plastic parts are used in the power module, then various components can be held and aligned, but the production of those parts may result in defects and impermissible tolerances stacking up
Solution Approach 1:
By integrating alignment features and component mounting structures directly into the molded battery module housing, the patent eliminates multiple separate alignment parts. This reduces the number of interfaces where tolerances could accumulate, while still providing precise positioning for the cell stack and electronic components through the housing's integrated features.
3Strength
If plastic parts are used in the power module, then mechanical fixing and component holding is achieved, but combustible material is provided in the event of thermal runaway
Solution Approach 1:
The patent employs a hybrid construction where the battery module housing is made of metal (steel or aluminum) for structural support and thermal runout resistance, while plastic materials are used only for non-critical components like insulation pads and seals. This composite approach maintains necessary mechanical fixing capabilities while minimizing combustible material in the event of thermal runaway.
Solution Approach 2:
The patent extracts the primary structural and safety functions from plastic components and assigns them to metal housing structures. Plastic parts are removed from load-bearing and high-temperature exposure roles, retaining only functions where their insulating and sealing properties are beneficial and where fire risk is minimal.
4Object-affected harmful factors
If a venting channel is added to direct high temperature gas away from components, then component protection is improved, but the device complexity increases
Solution Approach 1:
The venting channel is integrated directly into the battery module housing as an internal cavity or passage, rather than being a separate component. The housing itself forms the venting pathway, with vents strategically positioned to channel hot gas away from sensitive components. This merging approach provides thermal protection without adding external complexity.
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 solution effectively channels high-temperature gas away from sensitive components, reducing the risk of damage and improving manufacturing efficiency by simplifying the production process and enhancing safety through better sealing and structural integrity.
Implementation Method 1
the venting channel arranged to direct gas emitted from the cell vents towards a vent in the battery module housing
Implementation Method 2
The venting channel may comprise one or more tabs arranged to secure the venting channel to the battery module housing, such that the cell stack is held in position within the battery housing
Implementation Method 3
with insulating coatings and gaskets for improved sealing and protection
Implementation Method 4
with insulating coatings and gaskets for improved sealing and protection
Data Source
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AI summary
The present invention concerns a battery. More particularly, but not exclusively, this invention concerns a battery module comprising a battery module housing. A plurality of battery cells within the battery module housing comprise a cell vent configured to expel excess gas emitted from the battery cell. A venting channel comprises a plurality of venting apertures located aligned with the cell vents, and is arranged to direct gas emitted from the cell vents towards a vent in the battery module housing. The venting channel also secures the cell stack in position within the battery housing and comprises a plurality of wiring apertures. Battery module wiring passes through the wiring apertures and runs along the venting channel.