High-altitude multi-physics-field coupled battery thermal runaway testing device and method

Abstract

The invention discloses a high-altitude multi-physics field coupled battery thermal runaway test device and method.The battery thermal runaway test device adopts a nested double-cabin framework and comprises an inner cabin serving as a thermal runaway reaction kettle and an outer cabin serving as a dynamic pressure variable temperature test cabin, and the outer cabin is used for simulating a high-altitude environment; the battery is indirectly acted on the battery in the inner cabin through the inner cabin; the inner cabin is provided with a thermal runaway unit and a data acquisition unit for monitoring thermal runaway real-time temperature, pressure and gas components of the battery; the outer cabin is provided with a high-altitude environment simulation device, the outer cabin and the inner cabin are in coupling connection through a cross-cabin coupling unit, and cross-scale coupling of multiple physical fields at least including air pressure, temperature, ultraviolet radiation and microgravity and battery thermal runaway is achieved. The device is combined with a matched test method, so that the influence mechanism of multi-physics field coupling on the thermal runaway of the battery can be accurately explored, and a reliable basis is provided for high-altitude safety assessment of the battery.

Description

Technical Field

[0001] This invention relates to the field of battery thermal runaway testing technology, and in particular to a battery thermal runaway testing device and method with high-altitude multi-physics coupling. Background Technology

[0002] As the new energy industry extends to plateau regions and the aerospace field, the need for scenario adaptability in battery safety testing is becoming increasingly urgent. In applications such as new energy vehicles, drones, and energy storage power stations at high altitudes, the incidence of battery thermal runaway accidents is higher than in plains areas. The core cause lies in the strong coupling effect between the unique high-altitude environment and battery failure mechanisms. For example, at an altitude of 5000m, the air pressure is only 53% of that at sea level, and the ultraviolet radiation intensity reaches 450-500 W / m². Furthermore, aerospace scenarios involve a microgravity environment of 0.3-0.5g. These factors collectively lead to a lower battery thermal runaway trigger threshold and altered diffusion paths, rendering traditional testing methods inadequate for safety assessment requirements.

[0003] High-altitude environments affect battery safety performance through a triple pathway of "material degradation - accelerated reaction - diffusion mutation", specifically manifested as: (1) Material aging effect of strong ultraviolet radiation: The proportion of UVB (280-320nm) in high-altitude ultraviolet radiation is significantly increased (UVB accounts for 20% at 5000m altitude), causing the thickness of the aluminum oxide layer of the battery to increase to 3 times the initial value within 30 days, and the intensity of the carbonyl characteristic peak of the sealant to increase by 40%, directly causing a decrease in the sealing performance of the casing, an increase in the risk of electrolyte leakage, and a shortening of the thermal runaway trigger time. (2) Abnormal heat transfer under low pressure: The thermal conductivity of air decreases under low pressure, the heat dissipation efficiency of the battery decreases, and at the same time, the expansion rate of gases such as H2 and CO generated by thermal runaway is accelerated, causing the internal pressure of the battery to rise rapidly several times faster than in the plain environment, exacerbating the risk of casing rupture and gas explosion. (3) Changes in diffusion paths due to microgravity: In scenarios such as drones and high-altitude helicopters, the microgravity environment of 0.3-0.5g causes the thermal runaway flame morphology to change from "columnar" to "spherical," expands the thermal radiation range, and reduces the gas diffusion coefficient, resulting in local accumulation of toxic gas concentrations exceeding the standard. These cross-scale and multi-dimensional influence mechanisms make it impossible for traditional "single factor" or "binary factor" tests to reproduce the real failure process, becoming a core bottleneck restricting the development of high-altitude battery safety technology.

[0004] Current research on battery thermal runaway testing at home and abroad mainly focuses on three directions, but all of them have significant limitations: (1) Conventional environmental testing devices: represented by cylindrical battery testing fixtures, thermal runaway monitoring is achieved through sealed chambers, heating wires and temperature and pressure sensors, but they can only simulate the module space limitations under normal temperature and pressure, without involving any high-altitude environmental parameters, and the test results deviate from the actual plateau scenario. (2) Simple high-altitude simulation system: some research institutions add air pressure regulation modules on the basis of conventional environmental chambers, but do not consider ultraviolet radiation and microgravity factors, and adopt a single chamber design. The high temperature generated by thermal runaway will cause the temperature control system inside the chamber to fail, and there will be errors in parameter measurement. (3) Plateau field testing method: the test platform is built in areas above 3000m for field verification, but there are problems such as high test cost, uncontrollable environmental parameters, and long test cycle, which cannot meet the needs of batch testing and mechanism research.

[0005] In summary, existing technologies generally suffer from common defects such as "incomplete environmental simulation, poor parameter coupling, and low test accuracy," making it impossible to achieve cross-scale collaborative testing of high-altitude multi-physics fields and battery thermal runaway reactions.

[0006] Patent application CN206773155U discloses a secondary battery thermal runaway testing device, comprising: a test chamber with a test cavity for placing a secondary battery sample; a gas distribution system connected to the test cavity for regulating the gas pressure within the test cavity; a temperature control system for regulating the temperature of the test cavity; a first temperature sensor placed at the test location of the secondary battery sample and electrically connected to a data acquisition device; and a battery operating system. This secondary battery thermal runaway testing device can provide controllable coupled environmental parameters such as pressure and temperature, thereby enabling the study of the heat release characteristics and thermal runaway patterns of secondary batteries during charging and discharging under controllable complex gas pressure, temperature, and their coupling effects.

[0007] Patent application CN223123984U discloses a thermal management system for energy storage batteries based on a shallow underground cold source in high-altitude, frigid regions. The system includes a battery box, liquid-cooled piping, air piping, and a control system. The battery box houses battery modules, a PTC heating film, a liquid-cooled plate, and a phase change material. The liquid-cooled piping utilizes the shallow underground soil of the frigid region as a cold source for heat dissipation through an underground liquid-cooled tank. The air piping allows low-density, low-thermal-conductivity air from high-altitude regions to be introduced into the battery box's interlayer, creating significant thermal resistance and achieving thermal insulation. The system provides heat for low-temperature preheating of the battery modules through the PTC heating film and electric heaters in the liquid-cooled piping, and achieves rapid heating through thermal insulation in the battery box's air interlayer. The coolant in the liquid-cooled piping exchanges heat through the shallow underground cold source, absorbing heat from the battery modules in the battery box's interlayer and liquid-cooled plate, achieving effective heat dissipation.

[0008] Patent application CN217112644U discloses a lithium battery aging test system capable of simulating high-altitude temperature, humidity, and pressure. The test system includes a data acquisition system, a temperature controller, a humidity controller, a pressure controller, and a cyclic aging platform module. The cyclic aging platform module includes a vacuum-sealed spherical chamber, which comprises a cyclic charge-discharge platform and a vacuum pump. This utility model's test system is designed based on actual high-altitude flight environments, incorporating multi-scale coupled environments such as pressure, temperature, and humidity. The specially designed vacuum-sealed spherical chamber features a vacuum-sealed connector on its right side for external connection, providing a quick interface for data acquisition and battery cyclic aging testing. The sealed test spherical chamber is insulated, ensuring accuracy and reliability, and enabling multi-scale cyclic aging tests under complex battery environments. The data acquisition system provides accurate, timely, and delay-free data acquisition.

[0009] In summary, existing battery thermal runaway testing methods have significant shortcomings in high-altitude environments. Traditional testing methods often focus only on the two single or binary environmental factors of air pressure and temperature, completely ignoring the strong ultraviolet radiation unique to high-altitude regions and the microgravity environment in special scenarios such as aerospace. In fact, strong ultraviolet radiation causes oxidative degradation of battery casings, sealants, and other materials, significantly reducing the thermal runaway trigger threshold; while the microgravity environment alters the diffusion path of high-temperature gases and the flame morphology generated by thermal runaway, causing traditional ground-based test data to be severely distorted in high-altitude or aerospace scenarios. From the perspective of the entire vehicle, special application scenarios involving high-altitude areas are particularly relevant. In some high-altitude areas with harsh natural environments, such as terrains spanning plains, mountains, and plateaus, the altitude varies greatly, ranging from hundreds to thousands of meters, with significant fluctuations in air pressure and temperature. The typical characteristics of these conditions (low air pressure, low temperature, and thin air) significantly alter the thermal behavior of lithium-ion batteries.

[0010] Furthermore, existing testing devices suffer from structural design flaws. The single-chamber design means that the high temperatures and gases generated by the thermal runaway reaction can interfere with the accuracy of environmental simulations. For example, the high temperatures can damage the internal temperature control system, and the released gases may contaminate the equipment inside the chamber, making it impossible to accurately measure the impact of environmental factors on thermal runaway and hindering independent monitoring of environmental factors and reaction parameters. Moreover, its data acquisition and analysis methods are relatively outdated, making it impossible to conduct a full-chain correlation study from microscopic material aging to macroscopic thermal runaway behavior.

[0011] Current international standards (such as ISO 16750-2) and domestic testing specifications are based on plain environments, only involving combined tests of conventional temperatures (-40℃ to 85℃) and standard atmospheric pressure (101kPa), failing to cover the synergistic effects of multiple physical fields at high altitudes. Data from the promotion of new energy vehicles in plateau regions shows that batteries that pass traditional tests have insufficient accuracy in thermal runaway warnings during actual use. Therefore, it is necessary to develop specialized testing technologies adapted to the complex environments of high altitudes. Summary of the Invention

[0012] The purpose of this invention is to overcome the shortcomings and defects of existing technologies by providing a battery thermal runaway testing device and method with high-altitude multi-physics coupling. The battery thermal runaway testing device adopts a nested dual-chamber architecture, enabling precise coupling of multiple environmental parameters with the thermal runaway response. By combining this device with supporting testing methods, the influence mechanism of multi-physics coupling on battery thermal runaway can be accurately investigated, providing a reliable basis for battery safety assessment at high altitudes.

[0013] One objective of this invention is to provide a high-altitude multi-physics field coupled battery thermal runaway testing device, employing a nested dual-chamber architecture, including an inner chamber serving as a thermal runaway reactor and an outer chamber serving as a dynamic pressure and temperature-variable test chamber. The outer chamber is used to simulate a high-altitude environment and indirectly acts on the battery placed in the inner chamber through the inner chamber. The inner chamber is equipped with a thermal runaway unit and a data acquisition unit for monitoring the real-time temperature, pressure, and gas composition of the battery thermal runaway. The outer chamber is equipped with a high-altitude environment simulation device. The outer chamber and the inner chamber are coupled together through a cross-chamber coupling unit to achieve cross-scale coupling of at least multiple physical fields, including air pressure, temperature and humidity, ultraviolet radiation, and microgravity, with battery thermal runaway.

[0014] Preferably, the cross-cabin coupling unit includes a magnetic levitation coupling, through which the outer cabin and the inner cabin are connected, enabling the inner cabin to float stably during microgravity simulation; the magnetic levitation coupling includes a lever arm arranged on the side, which passes through the outer cabin and enters the interior to be connected and fixed to the outer wall surface of the inner cabin.

[0015] Preferably, the cross-compartment coupling unit includes at least one pressure balancing pipe, through which the inner compartment and the outer compartment are connected and coupled.

[0016] Preferably, a solenoid valve is connected in series on the pressure balancing pipe and connected to the main controller. The main controller adjusts the valve opening of the solenoid valve in real time according to the changes in air pressure inside the outer cabin to ensure that the air pressure inside the cabin is synchronized with that inside the cabin.

[0017] Preferably, the cross-compartment coupling unit includes at least one glass light-transmitting window disposed on the bulkhead of the inner compartment for ultraviolet light to pass through and irradiate the battery.

[0018] Preferably, the high-altitude environment simulation device includes: The air pressure regulation module is used to control the operation of the vacuum pump to regulate the dynamic stability of the air pressure inside the outer cabin, simulating the high-altitude air pressure environment. The temperature control module is used to control the operation of the cooling and heating plates based on the temperature signal inside the outer cabin. The ultraviolet radiation module is used to control the xenon lamp array to generate ultraviolet radiation and adjust the filters of the optical lens group according to the spectrum to simulate the ultraviolet spectral characteristics at different altitudes. The microgravity simulation module, connected to the magnetic levitation coupling, is used to generate a controllable magnetic field by forming a magnetic levitation platform through an electromagnet array. Based on magnetic levitation technology, the magnetic levitation coupling is used to simulate the gravity field of the inner cabin.

[0019] Preferably, the air pressure regulation module further includes a high-precision air pressure sensor for real-time monitoring of air pressure values ​​and feeding the air pressure data back to the main controller. The main controller then uses a PID algorithm to adjust the opening of the CNC needle valve connected to the vacuum pump to achieve dynamic stabilization of the air pressure inside the outer cabin.

[0020] Preferably, the thermal runaway unit includes a heating element for achieving rapid local heating of the battery and a puncture unit for puncturing the battery.

[0021] Preferably, the data acquisition unit includes: The temperature monitoring module uses several thermocouples, distributed on the surface of the battery under test or embedded inside the battery, to realize real-time monitoring of the three-dimensional temperature field of the battery. The pressure monitoring module uses pressure sensors located on the top of the inner compartment to measure the pressure changes inside the inner compartment during battery thermal runaway. The gas analysis module uses gas chromatography-mass spectrometry to sample the gases generated by the thermal runaway of the battery in the inner chamber for component analysis.

[0022] Another objective of this invention is to provide a high-altitude multi-physics field coupled battery thermal runaway testing method, implemented based on the aforementioned high-altitude multi-physics field coupled battery thermal runaway testing device, comprising the following steps: S1: Record the information of the sample to be tested before the test begins; S2: Place the sample to be tested in the inner chamber and clamp it with a fixture, and arrange the thermal runaway unit; S3: Place the inner cabin inside the outer cabin and monitor the pressure values ​​of the inner and outer cabins in real time to make the pressure of the inner and outer cabins the same; S4: Set the test environment temperature, humidity, pressure, ultraviolet intensity, and microgravity intensity, and let it stand until it reaches equilibrium; S5: Activate the thermal runaway unit to trigger thermal runaway in the battery; S6: Collect the gas generated by thermal runaway and analyze the changes in gas composition before and after the test; S7: Stop the thermal runaway unit when the battery reaches a preset cutoff condition. S8: Collect the powder remaining after battery combustion and analyze and characterize its components.

[0023] This invention, through innovative device architecture and testing methods, achieves cross-scale coupling of multiple physical fields such as air pressure, temperature and humidity, ultraviolet radiation, and microgravity with battery thermal runaway reactions. It accurately simulates complex high-altitude environments, independently monitors the thermal runaway reaction process, and conducts full-chain analysis from microscopic material degradation to macroscopic thermal runaway behavior, providing a reliable and comprehensive technical solution for battery safety assessment in high-altitude and special scenarios.

[0024] This invention employs a nested dual-chamber architecture, enabling precise coupling of multiple environmental parameters with thermal runaway reactions. The high-altitude environment simulated in the outer chamber indirectly affects the battery through the reactor shell of the inner chamber, while the inner chamber independently monitors real-time thermal runaway parameters (such as internal pressure and gas composition), avoiding interference from the outer chamber environment. Secondly, it balances safety and operability. The inner chamber, as the first barrier, can control the spread range of thermal runaway flames and toxic gases. Simultaneously, the small size of the inner chamber facilitates the integration of high-precision sensors (such as nano-thermocouples), while the large size of the outer chamber is suitable for installing large-scale simulation equipment such as ultraviolet radiation modules and microgravity simulation devices. Finally, it enables variable isolation and comparative testing. By controlling the parameters of the outer chamber and maintaining consistent initial conditions in the inner chamber, precise verification of the impact of a single environmental factor on thermal runaway can be achieved, meeting the innovative requirements of multi-factor coupling mechanism research.

[0025] This invention simulates the high-altitude environment in the outer chamber, while the inner chamber synchronizes environmental parameters through a pressure balancing pipe and a quartz light-transmitting window, ensuring that the thermal conductivity and gas diffusion characteristics of the battery materials in the thermal diffusion test are consistent with actual high-altitude conditions. Compared with traditional single-field thermal diffusion tests, it can reduce the measurement error of the thermal runaway gas diffusion coefficient and accurately reflect the real scenario of accelerated thermal diffusion rate and changes in material thermal conductivity caused by ultraviolet radiation under low atmospheric pressure at high altitudes.

[0026] This invention's dual-chamber design, through physical space separation and system linkage, achieves functional modularity and maximizes testing efficiency. Environmental parameters can be independently controlled to avoid cross-interference; parallel testing in multiple scenarios supports flexible combinations of test conditions, improving research efficiency. Compared to traditional single-environment testing, multi-physics coupling simulation more closely resembles real-world operating conditions, and test data can be directly used to construct battery life prediction models for high-altitude scenarios.

[0027] This invention, through multiphysics coupling technology, is shifting the understanding of the impact mechanism of high-altitude environments on batteries from "single-factor analysis" to "full-scenario dynamic simulation," providing crucial support for breakthroughs in energy storage technology under extreme conditions. Furthermore, the dual-chamber structure inherently possesses a fault isolation mechanism to ensure system safety. The two chambers have independent power supply, temperature control, and pressure systems; if one chamber experiences an anomaly, the other can continue operating, preventing a complete system shutdown. During high-risk thermal runaway tests in the inner chamber, the outer chamber can maintain normal environmental simulation, ensuring that other tests are unaffected. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the high-altitude multi-physics field coupling battery thermal runaway testing device of the present invention.

[0029] Figure 2 This is a flowchart of the battery thermal runaway test method using high-altitude multi-physics coupling according to the present invention.

[0030] Figure 3 This is a schematic diagram of the test device for thermal runaway of lithium-ion batteries, taking a square-shell battery cell as an example.

[0031] Figure 4 This is a schematic diagram showing the connection between the inner and outer cabins of the high-altitude multi-physics field coupling battery thermal runaway test device of the present invention.

[0032] Figure 5 This is a schematic diagram of the test method for evaluating the degree of thermal runaway of a single battery cell under high-altitude conditions, as presented in this invention. Detailed Implementation

[0033] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0034] This invention relates to a high-altitude multi-physics field coupled battery thermal runaway testing device, which employs a nested dual-chamber architecture to construct a thermal diffusion simulation environment synergistically involving four fields: air pressure, temperature and humidity, ultraviolet radiation, and microgravity. The nested dual-chamber architecture enables cross-scale coupling of environmental parameters and the thermal diffusion process. The device consists of an outer chamber (dynamic pressure and temperature variable-temperature test chamber), an inner chamber (thermal runaway reaction vessel), and a cross-chamber coupling unit. The outer chamber simulates the harsh and complex environment of high-altitude regions, encompassing physical fields such as air pressure, temperature, humidity, ultraviolet radiation, and microgravity. The inner chamber independently isolates the battery thermal runaway reaction process. The cross-chamber coupling unit enables the controllable transfer of environmental parameters from the outer chamber to the inner chamber, ensuring that the inner chamber test environment is highly consistent with actual high-altitude operating conditions.

[0035] Please see Figure 1 As shown in the exemplary embodiment of this application, the high-altitude multi-physics field coupled battery thermal runaway test device adopts a nested dual-chamber architecture, consisting of an outer chamber (dynamic pressure and temperature change test chamber), an inner chamber (thermal runaway reaction vessel), and a cross-chamber coupling unit. The outer chamber is used to simulate the complex environment at high altitude, the inner chamber independently isolates the battery thermal runaway reaction, and the cross-chamber coupling unit realizes the controllable transmission of environmental parameters from the outer chamber to the inner chamber. The three work together to form a decoupled test system of "environmental simulation-reaction monitoring". The outer chamber and the inner chamber are connected and coupled to each other through the cross-chamber coupling unit. The inner chamber is equipped with a thermal runaway unit and a data acquisition unit for monitoring the real-time temperature, pressure, and gas composition of the battery thermal runaway. The outer chamber is equipped with a high-altitude environment simulation device to realize the cross-scale coupling of multi-physics fields, including at least air pressure, temperature and humidity, ultraviolet radiation, and microgravity, with battery thermal runaway.

[0036] In this embodiment of the application, the outer cabin serves as the core of the environmental simulation and integrates the following functional modules: The air pressure regulation module consists of a vacuum pump, an air pressure sensor, and a CNC needle valve. The vacuum pump regulates the air pressure inside the chamber to simulate a high-altitude environment; the high-precision air pressure sensor monitors the air pressure value in real time and feeds the data back to the main controller PLC. The PID algorithm is used to adjust the opening of the CNC needle valve to achieve dynamic air pressure stability.

[0037] Temperature control module: It adopts a combination of semiconductor cooling chip and ceramic heating element, with K-type thermocouple to realize temperature regulation. The main controller automatically switches between cooling and heating modes based on the thermocouple feedback signal.

[0038] Ultraviolet radiation module: Equipped with a xenon lamp array and optical lens group to generate ultraviolet radiation; by adjusting the spectral filter, it can accurately simulate the ultraviolet spectral characteristics at different altitudes.

[0039] Microgravity simulation module: Based on magnetic levitation technology, a magnetic levitation platform is formed by an array of electromagnets, generating a controllable magnetic field to simulate a gravity field. The magnetic levitation platform, in conjunction with an accelerometer, provides real-time feedback of gravity values, ensuring the stability of the microgravity simulation.

[0040] In this embodiment, the inner chamber is an independent device structure, which may be made of stainless steel. The internal structure design is centered on ensuring safe monitoring of thermal runaway reactions, and includes: Thermal runaway units, such as those integrating heating elements and needle-piercing units, can achieve rapid localized heating using heating elements; the needle-piercing unit is driven by an electric push rod, with adjustable needle-piercing speed and replaceable needle diameter to meet the needs of different triggering scenarios.

[0041] Temperature monitoring module: A large number of K-type thermocouples are arranged, which can be distributed on the battery surface or implanted inside the battery according to actual needs, to realize real-time monitoring of the three-dimensional temperature field.

[0042] Pressure monitoring module: It adopts a piezoresistive pressure sensor, which is installed on the top of the reactor to directly measure the internal pressure changes during the thermal runaway process.

[0043] Gas Analysis Module: A gas sampling port is set up to connect to an external gas chromatograph-mass spectrometer (hereinafter referred to as GC-MS instrument), which can analyze multiple gas components such as H2, CO, and HF in real time.

[0044] In this embodiment of the application, the cross-cabin coupling unit, as the key to the coordination between the inner and outer cabins, includes: Pressure balancing pipe: Stainless steel is recommended, with both ends welded to the outer cabin sidewall and the inner cabin top, respectively. A fast-response solenoid valve is connected in series on the pipe. The main controller adjusts the valve opening in real time according to changes in the outer cabin pressure to ensure that the inner cabin pressure is synchronized with the outer cabin pressure.

[0045] Quartz light-transmitting window: It adopts a double-sided anti-reflective coating process and is embedded in the side wall of the outer cabin, facing the battery sample in the inner cabin, to ensure efficient penetration of ultraviolet radiation from the outer cabin, while preventing strong light from thermal runaway from interfering with the equipment outside the cabin.

[0046] Magnetic levitation coupling: The outer and inner cabins are connected by a magnetic levitation coupling, allowing the inner cabin to levitate stably during microgravity simulation. For example, the magnetic levitation coupling includes a lever arm arranged on the side, which passes through the outer cabin and enters the interior to be fixedly connected to the outer wall surface of the inner cabin. A neodymium iron boron permanent magnet array is used, utilizing Lorentz force to transmit microgravity signals, achieving contactless gravity transmission and avoiding interference from mechanical connections in the microgravity simulation.

[0047] High-temperature resistant shielded cable: The insulation layer and sheath are made of special high-temperature resistant materials, which can maintain good physical properties in high-temperature environments. This ensures that the temperature, pressure, gas composition and other data collected by the internal sensor array are stably transmitted to the external main controller PLC. The high-temperature resistant shielded cable is wrapped with a metal shielding layer, which can effectively shield external electromagnetic interference and prevent electromagnetic noise from being superimposed on the sensor signal, thus ensuring the accuracy of the transmitted data.

[0048] This invention's device enables component connection and collaborative operation. The inner chamber is flexibly connected to the outer chamber's microgravity platform via a bottom magnetic levitation coupling, ensuring stable levitation of the inner chamber during microgravity simulation. It also supports water immersion for verifying sealing tests. Gas communication between the outer and inner chambers is achieved through a pressure balancing pipe, while ultraviolet radiation penetration is achieved through a quartz light-transmitting window. Data from the inner chamber's sensor array is transmitted to the outer chamber's main controller via a high-temperature shielded cable. Environmental parameter sensor signals from the outer chamber are promptly and accurately transmitted to the main controller's PLC. According to a preset test procedure, the main controller PLC first adjusts the outer chamber's environmental parameters to the target value. Once the parameters stabilize, it synchronizes the environmental conditions of the inner chamber with the pressure balancing pipe, quartz light-transmitting window, and magnetic levitation coupling. Subsequently, it triggers the inner chamber's heating element or needle penetration unit to simultaneously collect data from both the inner and outer chambers, achieving thermal runaway testing under multi-physics coupling.

[0049] This invention also provides a high-altitude multi-physics field coupled battery thermal runaway testing method, implemented based on the high-altitude multi-physics field coupled battery thermal runaway testing device, including the following steps: S1: Record the information of the sample to be tested before the test begins; S2: Place the sample to be tested in the inner chamber and clamp it with a fixture, and arrange the thermal runaway unit; S3: Place the inner cabin inside the outer cabin and monitor the pressure values ​​of the inner and outer cabins in real time to make the pressure of the inner and outer cabins the same; S4: Set the target ambient temperature, humidity, pressure, ultraviolet intensity, and microgravity intensity for the test, and let it stand until it reaches equilibrium; S5: Activate the thermal runaway unit to trigger thermal runaway in the battery; S6: Collect the gas generated by thermal runaway and analyze the changes in gas composition before and after the test; S7: Stop the thermal runaway unit when the battery reaches a preset cutoff condition. S8: Collect the powder remaining after battery combustion, analyze and characterize its composition, or perform failure analysis, etc.

[0050] During the test, it was determined whether the air pressure inside the inner and outer chambers was consistent. If they were inconsistent, the solenoid valve of the pressure balancing pipe was adjusted. Figure 3 The pressure relief valve is adjusted to make the air pressure inside and outside the cabin equal before triggering thermal runaway.

[0051] Among them, key data during the test are collected through the set sensors and data acquisition modules, such as battery voltage and temperature, ambient temperature, humidity, gravity field, ultraviolet radiation intensity data, battery image data during the test, thermal runaway gas, and air pressure data inside the chamber.

[0052] The high-altitude multi-physics coupling battery thermal runaway test method of this invention consists of the following stages: (1) Environmental preconditioning stage: Set the target test environment parameters in the main controller, including air pressure, temperature, humidity, ultraviolet radiation intensity and microgravity value. Before the test, the air pressure regulation module is activated first in the outer cabin to adjust the air pressure to the target value through the vacuum pump; after the air pressure stabilizes, the temperature control module, ultraviolet radiation module and microgravity simulation module are activated simultaneously to make the temperature, humidity, ultraviolet radiation and microgravity in the outer cabin reach the set parameters to ensure that the environmental conditions are fully stable.

[0053] (2) Inner Chamber Environment Synchronization Stage: After the outer chamber environmental parameters stabilize, the main controller controls the cross-chamber coupling unit to work. The solenoid valve on the pressure balance pipe opens, and the air pressure in the inner chamber is synchronized with the air pressure in the outer chamber through the pressure balance pipe; the quartz light-transmitting window allows ultraviolet radiation from the outer chamber to penetrate into the inner chamber and irradiate the battery sample; the magnetic levitation coupling transmits the simulated microgravity signal from the outer chamber to the inner chamber, and the acceleration sensor in the inner chamber provides real-time feedback of the gravity value to ensure that the inner chamber environment is consistent with the height of the outer chamber.

[0054] (3) Thermal runaway triggering and monitoring stage: Battery thermal runaway is triggered by the internal triggering device (such as heating plate or needle penetration unit). At the same time as thermal runaway is triggered, the thermocouples, pressure sensors, gas sampling ports in the internal compartment and the PIV flow field instrument in the external compartment start to collect data simultaneously. The temperature sensor (thermocouple) collects the temperature data of the battery surface and internal temperature; the pressure sensor monitors the pressure change in the internal compartment; the GC-MS instrument connected to the gas sampling port analyzes the gas composition generated by thermal runaway in real time, and the PIV flow field instrument in the external compartment records the gas flow trajectory during thermal runaway. All data are transmitted to the main controller through high temperature shielded wire.

[0055] (4) Multi-field coupling analysis and report generation stage: The main controller has a built-in edge computing module to perform real-time filtering on the collected temperature, pressure and other data (such as Kalman filtering algorithm), and extract feature spectral lines from the gas composition data through Fast Fourier Transform (FFT). After the test, a test report is generated that includes environmental parameters, thermal runaway characteristic parameters, risk assessment results and process image records.

[0056] (5) Residual failure analysis stage: After the temperature drops and returns to room temperature, collect the residual sample powder and perform morphological characterization, composition analysis and structural characterization as required, such as transmission electron microscopy (TEM), scanning electron microscopy (SEM), atomic force microscopy (AFM), X-ray photoelectron spectroscopy (XPS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrophotometer (AAS), infrared spectroscopy (FT-IR), Raman spectroscopy, dynamic light scattering (DLS), nanoparticle tracking analysis (NTA), X-ray diffraction (XRD) etc.

[0057] like Figure 3 As shown, taking a square battery cell as an example, this embodiment of the invention provides a test device for evaluating the degree of thermal runaway of a square battery cell in a high-altitude environment. The inner and outer chambers are connected by a magnetic levitation coupling 50. Specifically, the magnetic levitation coupling 50 includes a lever arm 51 arranged on the side, which passes through the outer chamber 10 and enters the interior to be connected and fixed to the outer wall surface of the inner chamber 20. The test object 40 (square battery cell) is placed inside the inner chamber 20 (thermal runaway reactor) inside the outer chamber 10. The heating element 22 for thermal runaway is arranged at the thermal runaway trigger point of the test object, and thermocouples are attached at the required temperature acquisition points. At the same time, voltage acquisition lines are connected to the positive and negative terminals of the battery to acquire voltage. A pressure balance tube 30 and a pressure sensor 21 are arranged between the inner and outer chambers to monitor whether the pressure in the inner and outer chambers has reached equilibrium in real time. An ultraviolet radiation module 11 is arranged in the outer chamber to provide ultraviolet radiation to the battery, and an ultraviolet radiometer is arranged to acquire ultraviolet intensity. An ultraviolet spectrometer is arranged to detect the spectrum and adjust the filter to adjust the ultraviolet intensity. If an imbalance occurs, adjust the valve on the solenoid valve on the pressure balancing pipe to connect the inner and outer cabins. Preset test parameters in the main controller, adjust the outer cabin air pressure, and set parameters such as temperature, humidity, ultraviolet radiation intensity, and microgravity; select heating element triggering for the inner cabin.

[0058] Figure 3 The lithium-ion battery thermal runaway test device, using the square battery cell shown as an example, can be operated according to the following procedure:

[0059] The external cabin equipment is activated, and the air pressure regulation module is started to regulate the air pressure. After the air pressure stabilizes, the temperature control module is activated to adjust the temperature and humidity inside the cabin to the target temperature and humidity and maintain them constant. At the same time, the xenon lamp array is turned on, and the ultraviolet radiation intensity and spectral distribution are adjusted to the set values ​​through the detected spectral adjustment filter. The magnetic levitation platform of the microgravity simulation module maintains gravity output. During this stage, the system remains stationary to ensure that the environmental parameters are stable. The main controller controls the opening of the solenoid valve on the pressure balance pipe to achieve pressure synchronization between the inner and outer chambers; the quartz light-transmitting window introduces ultraviolet radiation from the outer chamber into the inner chamber to irradiate the surface of the battery sample; the magnetic levitation coupling stably transmits the gravity signal to the inner chamber, and the acceleration sensor in the inner chamber provides real-time feedback of the gravity value to confirm consistency with the outer chamber. The heating element inside the inner chamber is activated to heat the battery until thermal runaway occurs; battery temperature data is collected in real time via thermocouples; pressure sensors monitor pressure changes between the inner and outer chambers; and a GC-MS instrument connected to the gas sampling port analyzes the gas composition in real time and records the gas flow trajectory during thermal runaway.

[0060] The main controller processes the collected data, such as using a Kalman filter algorithm to filter temperature and pressure data in real time, and extracting gas component characteristic spectral lines through a Fast Fourier Transform (FFT). After the test, a test report is generated, including environmental parameters, thermal runaway characteristic parameters, risk assessment results, and process video recordings. During the test, pre-set pipelines are used, such as... Figure 3 As shown, the inner and outer compartments are each connected to a pipeline to discharge the gas and liquid phases generated during the test, in order to collect the waste gas and waste liquid and treat the waste gas and waste liquid after the test is completed; After the temperature drops and returns to room temperature, the residual sample powder is collected and subjected to morphological characterization, compositional analysis, and structural characterization as required, such as transmission electron microscopy (TEM), scanning electron microscopy (SEM), atomic force microscopy (AFM), X-ray photoelectron spectroscopy (XPS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrophotometry (AAS), Fourier transform infrared spectroscopy (FT-IR), Raman spectroscopy, dynamic light scattering (DLS), nanoparticle tracking analysis (NTA), and X-ray diffraction (XRD).

[0061] like Figure 5 As shown in the figure, this application provides a test operation method for evaluating the degree of thermal runaway of a single battery cell in a high-altitude environment. The specific process is as follows: S1: Before the test begins, sample pretreatment is performed: information such as the appearance, open-circuit voltage, thickness, mass, and capacity of the individual battery cells is recorded; S2: Place the battery cell to be tested inside the inner chamber (thermal runaway reactor), fix it with clamps, and set up heating elements. Connect the voltage acquisition line, temperature acquisition line, pressure sensor, etc. of the cell at appropriate positions. S3: Place the inner chamber (reactor) inside the outer chamber (dynamic pressure and temperature test chamber), and extend pressure balancing pipes according to the diameters of the inner and outer chambers. Install pressure sensors at these pipes to monitor the pressure values ​​in real time. Control the connection between the inner and outer chambers using a pressure relief valve based on the pressure difference, ensuring equal pressure in both chambers. The exhaust pipe connected to the inner chamber should be routed to a gas collection device as needed, and connected to a gas analysis device. S4: Select and set parameters such as temperature, humidity, pressure, ultraviolet intensity, and microgravity intensity according to the test requirements, and let it stand until it reaches equilibrium, that is, stabilizes to the target environmental conditions; S5: Set the desired temperature rise rate, start the heating program, and begin heating; S6: Collect gas periodically according to actual needs, analyze the changes in gas composition before and after the test using gas chromatography (GC), perform gas composition analysis, and collect temperature change data and voltage change data of the battery cell; S7: Cut-off condition: Heating can be stopped and the test ends when one of the following conditions is met: However, the data acquisition device must continuously monitor the real-time data of thermal runaway and record the entire thermal runaway process; The conditions include: sudden temperature change, sudden voltage drop, sudden increase in ambient pressure, explosion-proof valve opening (the sound of the explosion-proof valve cracking can be heard); visible open flame or salt spray; if the sample has BMS function, thermal runaway related signals appear; other abnormalities. S8: After the test, exhaust gas and waste liquid are treated, and the powder remaining after battery combustion is collected. Its main components are characterized by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), etc.

[0062] As can be seen from the above description, the technology of this application, through a nested dual-chamber architecture design, adopts a nested structure consisting of a dynamic pressure and temperature variable test chamber (outer chamber), a thermal runaway reactor (inner chamber), and a cross-chamber coupling unit. The outer chamber simulates the high-altitude multi-physics environment, while the inner chamber isolates the battery thermal runaway reaction. The cross-chamber coupling unit realizes the controllable transfer of environmental parameters, and the collaborative simulation and coupling control of multi-physics fields, achieving coupling of four fields: air pressure, temperature and humidity, ultraviolet radiation, and microgravity. This accurately simulates the complex high-altitude environment and provides a realistic and reliable high-altitude complex test environment for the inner chamber. The inner and outer chambers work independently while also realizing the mutual transfer of parameters, each performing its own function. This breaks through the traditional single-chamber test mode, solves the problem of the accuracy of thermal runaway reaction interference environment simulation, achieves decoupling of environmental simulation and reaction monitoring, and improves isolation, flexibility, and reliability at the system level.

[0063] This application achieves multi-physics coupling through an external cabin, including modules for adjusting air pressure, temperature and humidity, ultraviolet radiation, and microgravity. The main controller and host computer achieve temporal coupling of these parameters, such as pre-processing by adjusting air pressure before adjusting ultraviolet radiation, temperature and humidity, and microgravity parameters. This makes the testing conditions closer to actual high-altitude and aerospace scenarios, comprehensively and multidimensionally simulating the real environment of high-altitude regions. It allows for the exploration of the impact of various factors on battery performance. Through the synergistic effect of multi-physics, the complex mechanism of battery performance degradation under high-altitude conditions can be revealed. It also allows for the simultaneous exploration of the impact of single-factor and multi-factor coupling effects on lithium-ion batteries, providing crucial support for breakthroughs in energy storage technology under extreme environments.

[0064] In particular, the pressure balance tube of the cross-chamber coupling unit achieves pressure synchronization between the inner and outer chambers, the quartz light-transmitting window ensures efficient penetration of ultraviolet radiation, the magnetic levitation coupling transmits microgravity signals without contact, and the cross-chamber coupling unit combines the inner and outer chambers into one, jointly ensuring that the environmental parameters of the outer chamber are accurately transmitted to the inner chamber, providing a real and reliable testing environment for the inner chamber.

[0065] In this application, a multi-channel sensor array (such as thermocouples, pressure sensors, quantum dot gas sensors, etc.) is used to collect multi-dimensional data of the thermal runaway process in real time, and the protocol can achieve nanosecond-level time synchronization; it can be combined with digital twin models and quantum neural networks to perform real-time analysis of data and predict thermal runaway trends, realizing full-chain analysis from microscopic material degradation to macroscopic thermal runaway behavior.

[0066] In this application, the nested dual-compartment structure inherently incorporates a fault isolation mechanism to ensure system safety. At the hardware level, the independent system and physical isolation design achieve independent energy supply, isolated environmental control systems, and physical space separation, providing fire and explosion protection, and gas leak protection. At the software level, it features a distributed control system with independent control units, real-time fault diagnosis, data acquisition, and safety redundancy. Independent data channels and interlocking protection logic for both compartments ensure data storage isolation, achieving the effect that if one compartment fails, the other remains intact.

[0067] In summary, the advantages of this invention compared to the prior art are as follows: (1) Comprehensiveness and accuracy of environmental simulation: Breaking through the traditional binary model of "pressure-temperature", strong ultraviolet radiation and microgravity are incorporated into the test system to form a four-field coupled environmental simulation system. Through the xenon lamp ultraviolet radiation module and the magnetic levitation microgravity platform, the ultraviolet intensity and gravity value can be precisely adjusted and controlled in conjunction with air pressure, temperature and humidity. The simulation accuracy reaches the industry-leading level, making the test conditions closer to the actual scenarios of plateau and aerospace, and improving the reliability of test data.

[0068] (2) Innovation and practicality of the device architecture: The device adopts a nested dual-chamber architecture, with the outer chamber simulating a complex environment and the inner chamber isolating the thermal runaway reaction. The environmental parameters are controllably transmitted through cross-chamber coupling units such as pressure balance pipes and quartz light-transmitting windows. This design not only ensures the stability of the environmental simulation but also avoids the interference of the thermal runaway reaction on the environmental equipment. It can independently and accurately monitor various parameters during the thermal runaway process. Compared with the traditional single-chamber design, the test accuracy is high and the equipment service life is long.

[0069] (3) Advanced and scientific nature of the testing method: Combining cutting-edge technologies such as quantum dot sensors and femtosecond laser temperature measurement, picosecond-level response and nanometer-level monitoring are achieved, and multi-dimensional data are collected during the thermal runaway process. Using intelligent algorithms such as quantum neural networks and digital twins, a full-chain correlation model of "environmental factors-material degradation-thermal runaway behavior" is established. This model can not only predict the risk of thermal runaway in real time, but also reveal the origin mechanism of thermal runaway from the microscopic level, providing in-depth data support for the intrinsic safety design of batteries and filling the gap in mechanism research of traditional testing.

[0070] (4) Wide range and forward-looking application scenarios: This invention is not only applicable to battery testing in conventional high-altitude ground scenarios, but also meets the needs of special fields such as aerospace and plateau special equipment. Through reconfigurable modular design and self-optimizing algorithm, different test scenarios and parameter combinations can be quickly switched. The hardware reuse rate is high, and the test efficiency is improved. It provides key technical support for the application and development of batteries in extreme environments in the future.

[0071] This application's technology, by combining a high-altitude device with a thermal runaway device, explores the changing patterns of battery thermal characteristics under high-altitude environments. This allows for optimization of thermal management system design (such as improving air-cooling structures and increasing heat dissipation through phase change materials), thereby enhancing battery safety and lifespan in high-altitude regions. Simultaneously, it can facilitate the promotion of the new energy industry in high-altitude areas. For example, it can provide thermal management technology support for electric heavy-duty trucks and photovoltaic energy storage systems in high-altitude regions. At the academic level, it fills a gap in research on battery thermal characteristics under low-pressure environments, providing new research directions for interdisciplinary fields such as extreme environment electrochemistry and thermodynamics.

[0072] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention. Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of the equivalents of the claims be included within the invention.

[0073] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A high-altitude multi-physical field coupled battery thermal runaway testing device, characterized in that, The nested double cabin structure includes an inner cabin as a thermal runaway reaction kettle and an outer cabin as a dynamic pressure and temperature test cabin, the outer cabin is used for simulating a high altitude environment and indirectly acts on the battery placed in the inner cabin through the inner cabin; the inner cabin is provided with a thermal runaway unit and a data acquisition unit for monitoring the real-time temperature, pressure and gas composition of the battery thermal runaway; The outer cabin is arranged with a high altitude environment simulation device, and the outer cabin and the inner cabin are coupled and connected through a cross-cabin coupling unit to realize cross-scale coupling of at least multiple physical fields including air pressure, temperature and humidity, ultraviolet radiation and microgravity and battery thermal runaway.

2. The high altitude multi-physical field coupled battery thermal runaway testing device according to claim 1, wherein, The cross-cabin coupling unit includes a magnetic suspension coupling, and the outer cabin and the inner cabin are connected through the magnetic suspension coupling to enable the inner cabin to be stably suspended during microgravity simulation; the magnetic suspension coupling includes a rod lever arm arranged on the side surface, and the rod lever arm penetrates through the outer cabin and is connected and fixed to the outer wall surface of the inner cabin.

3. The high altitude multi-physical field coupled battery thermal runaway testing device according to claim 1, wherein, The cross-cabin coupling unit includes at least one pressure balance pipe, and the inner cabin and the outer cabin are connected and communicated through the pressure balance pipe.

4. The high altitude multi-physical field coupled battery thermal runaway testing device according to claim 3, wherein, An electromagnetic valve is arranged in series on the pressure balance pipe and is connected with a main controller, and the valve opening degree of the electromagnetic valve is adjusted in real time by the main controller according to the air pressure change in the outer cabin to ensure that the air pressure in the inner cabin is synchronized with the outer cabin.

5. The high altitude multi-physical field coupled battery thermal runaway testing device according to claim 1, wherein, The cross-cabin coupling unit includes at least one glass light-transmitting window arranged on the cabin wall of the inner cabin for ultraviolet light to irradiate the battery.

6. The high altitude multi-physical field coupled battery thermal runaway testing device according to claim 2, wherein, The high altitude environment simulation device includes: An air pressure adjusting module for controlling the action of a vacuum pump to adjust the air pressure in the outer cabin to be dynamically stable and simulate a high altitude air pressure environment; A temperature control module for controlling the operation of a refrigerating plate and a heating plate according to a temperature signal in the outer cabin; An ultraviolet radiation module for controlling a xenon lamp array to generate ultraviolet radiation and adjusting a filter of an optical lens group according to a spectrum to simulate different altitude ultraviolet spectrum characteristics; A microgravity simulation module for forming a controllable magnetic field through an electromagnet array to generate a magnetic suspension platform, and realizing the simulation of the gravity field of the inner cabin through a magnetic suspension coupling based on the magnetic suspension technology.

7. The high altitude multi-physical field coupled battery thermal runaway testing device according to claim 6, wherein, The air pressure adjusting module further includes a high-precision air pressure sensor for monitoring the air pressure value in real time and feeding back the air pressure value data to the main controller, and the opening degree of a numerical control needle valve connected with the vacuum pump is adjusted by the main controller through a PID algorithm to realize the dynamic stability of the air pressure in the outer cabin.

8. The high altitude multi-physical field coupled battery thermal runaway testing device according to claim 1, wherein, The thermal runaway unit includes a heating sheet for realizing local rapid heating of the battery and a needle piercing unit for piercing the battery.

9. The high altitude multi-physical field coupled battery thermal runaway testing device according to claim 1, wherein, The data acquisition unit includes: A temperature monitoring module using a plurality of thermocouples distributed on the surface of the battery to be tested or implanted in the battery to realize real-time monitoring of the three-dimensional temperature field of the battery; A pressure monitoring module using a pressure sensor arranged at the top of the inner cabin to measure the pressure change data in the inner cabin during the battery thermal runaway process; A gas analysis module using a gas chromatograph mass spectrometer to sample the gas generated by the battery thermal runaway in the inner cabin for component analysis.

10. A battery thermal runaway test method of high altitude multi-physical field coupling, characterized in that, The high altitude multi-physical field coupled battery thermal runaway test device according to any one of claims 1-9 is realized, including the following steps: S1: recording the information of the sample to be tested before the test starts; S2: placing the sample to be tested in the inner cabin with a clamp, and arranging a thermal runaway unit; S3: Place the inner tank in the outer tank, monitor the pressure values of the inner and outer tanks in real time, and make the pressure of the inner and outer tanks the same; S4: Set the test environment temperature, humidity, pressure, ultraviolet intensity, and microgravity intensity, and stand until equilibrium is reached; S5: Start the thermal runaway unit to trigger the thermal runaway of the battery; S6: Collect the gas generated by the thermal runaway and analyze the change of the gas composition before and after the test; S7: Stop the thermal runaway unit when the preset cutoff condition of the battery appears: S8: Collect the remaining powder after the battery burns and analyze and characterize the composition.

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