Pouch Cell Module Resin Barrier for Thermal Runaway Containment

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Solution Overview

Problem

Existing battery modules face issues with thermal propagation between cells and modules due to high-temperature gas and flame discharge, leading to potential serial ignition and thermal runaway.

Innovation Solution

A battery module structure with a resin layer coating the cell laminate, dividing the space between the laminate and the top plate into isolated spaces for each cell bank, using thermally conductive and fire-resistant materials to dissipate heat and prevent flame and gas discharge to adjacent cells and modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If multiple battery cells are laminated in a battery module to increase capacity, then energy density and output are improved, but thermal propagation between cells occurs when one cell ignites, causing serial ignition and thermal runaway

Engineering Contradiction:

Improveenergy densityVSAvoidthermal safety

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The battery module is divided into multiple isolated cell banks, where each bank contains a subset of battery cells. The resin layer acts as a thermal barrier that segments the module into independent thermal zones. When one cell ignites, the resin layer prevents heat and flame from propagating to other cell banks, thereby containing thermal runaway within a single bank while maintaining high energy density through the multi-cell configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A resin layer is introduced as an intermediary material between adjacent battery cells and cell banks. This resin layer serves as a thermal and flame barrier that mediates the interaction between cells during normal operation and during thermal events. The resin layer's fire-resistant properties block the transmission of high-temperature gas and flame, preventing thermal propagation while allowing the battery module to maintain its compact, high-density structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If battery cells are arranged in a compact laminate structure to reduce module size and weight, then integration density is improved, but space for heat dissipation and flame containment is reduced

Engineering Contradiction:

Improvemodule sizeVSAvoidheat dissipation capability

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

A resin layer is applied as a thin film coating on the battery cells within the laminate structure. This thin film provides thermal and flame barrier functions without significantly increasing the module's overall size or weight. The resin layer creates sufficient thermal isolation between cells while maintaining the compact laminate configuration, enabling both high integration density and adequate heat dissipation capability.

Inventive Principle:

Principle #30Flexible shells and thin films

3Stress or pressure

If high-temperature gas and flame are allowed to discharge freely from ignited cells, then pressure relief is achieved, but thermal propagation to adjacent cells and modules occurs

Engineering Contradiction:

Improvepressure reliefVSAvoidflame propagation

Core Design Contradiction:

Stress or pressureVSObject-generated harmful factors

Solution Approach 1:

The harmful thermal and flame discharge is extracted and contained within each cell bank by the resin layer barrier. The resin layer allows pressure to be managed within isolated zones while preventing the extraction of heat and flame to adjacent cell banks. This approach maintains pressure relief functionality for each individual cell while eliminating the propagation of thermal hazards to other parts of the battery module.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Prevents thermal runaway by isolating discharge paths for each cell bank, effectively dissipating heat and blocking flame propagation, thereby ensuring safety and stability of the battery module.

Implementation Method 1

using thermally conductive and fire-resistant materials to dissipate heat and prevent flame and gas discharge to adjacent cells and modules

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an upper surface of the cell laminate is coated with a resin layer having an upper surface in contact with the top plate... dividing the space between the laminate and the top plate into isolated spaces for each cell bank

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentEP4685932A1Battery module configured to prevent thermal propagation between cell banks

Publication Date: 2026.01.28 LG ENERGY SOLUTION LTD

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AI summary

The present invention provides A battery module including: a cell laminate wherein a plurality of pouch-type battery cells are laminated in widthwise direction; a frame accommodating the cell laminate with an open upper end; and a top plate covering the upper end of the frame, wherein an upper surface of the cell laminate is coated with a resin layer having an upper surface in contact with the top plate. The resin layer may extend in horizontal direction, and the resin layer may divide, in horizontal direction, a space between the cell laminate and the top plate into a plurality of spaces.