Pouch Cell Cover Assembly for Downward Battery Module Venting

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Solution Overview

Problem

Existing battery modules fail to effectively direct high-temperature gases and particles during thermal events, leading to potential damage and combustion due to gaps in assembly tolerances, and lack sufficient support and rigidity for pouch-type battery cells.

Innovation Solution

A battery module design featuring a cell cover that surrounds pouch-type battery cells and bus-bar frame assemblies, with a symmetrical structure and side openings, coupled to a bus-bar frame using grooves, and a module case with a gas venting hole at the bottom to direct venting gases downward.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cell units are assembled with bus-bar frame assembly using conventional methods, then assembly is straightforward, but gaps form due to assembly tolerances causing uncontrolled venting of gases and particles

Engineering Contradiction:

Improvedirectional venting performanceVSAvoidcell cover structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cell cover is divided into multiple functional segments: a main body portion covering the battery cells, a frame assembly covering the bus-bar frame, and side openings for controlled venting. This segmentation allows each part to perform its specific function while maintaining overall structural integrity and directional venting capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cell cover acts as an intermediary structure between the battery cells/bus-bar frame assembly and the external environment. It provides a controlled interface that allows thermal event gases to vent in a predictable direction while preventing uncontrolled discharge through assembly gaps.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If pouch-type battery cells are stored without additional support structures, then device complexity is reduced, but support and rigidity of the battery cells are insufficient

Engineering Contradiction:

Improvesupport and rigidity of pouch-type battery cellsVSAvoidcell cover structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The cell cover serves multiple functions simultaneously: it provides mechanical support and rigidity to the pouch-type battery cells, covers and protects the bus-bar frame assembly, and enables controlled directional venting during thermal events. This multi-functionality reduces the need for separate support structures.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cell cover merges the support function with the venting function by integrating a rigid structure that both reinforces the soft pouch-type battery cells and provides controlled pathways for gas discharge. The frame assembly portion further combines structural support with electrical component protection.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If conventional battery module assembly is used, then manufacturing is simpler, but thermal damage propagates to other battery modules due to uncontrolled venting

Engineering Contradiction:

Improvethermal damage propagationVSAvoidmodule case structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The cell cover converts the harmful thermal runaway event into a controlled process by providing designated venting pathways. Instead of allowing uncontrolled explosive venting that damages surrounding modules, the side openings and frame assembly guide the hot gases and particles in predictable directions, protecting other battery modules from thermal damage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Manufacturing precision

If assembly tolerances are reduced to eliminate gaps, then manufacturing precision increases, but assembly complexity and cost increase

Engineering Contradiction:

Improveassembly gap controlVSAvoidassembly process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The cell cover is designed with pre-formed frame assembly portions and side openings that accommodate the bus-bar frame assembly before final assembly. This preliminary structuring ensures proper alignment and gap control without requiring extremely tight assembly tolerances, as the cover itself provides the positioning framework.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250329853A1Battery module and battery pack including same

Publication Date: 2025.10.23 LG ENERGY SOLUTION LTD

AI summary

According to an embodiment of the present disclosure, a battery module may include a cell unit stack including a plurality of cell units stacked in one direction, a bus-bar frame assembly disposed inside the cell unit stack and configured to electrically connect pouch-type battery cells to each other, and a module case configured to store the cell unit stack and the bus-bar frame assembly. Each cell unit of the plurality of cell units may include at least one pouch-type battery cell, and a cell cover configured to surround the at least one pouch-type battery cell and the bus-bar frame assembly and have an open bottom. Additionally, a battery pack may include the battery module.