System for gas condensation and containment in li-ion battery thermal runaway

Abstract

A system for gas condensation and containment during a thermal runaway event is disclosed The system comprises an enclosure 110. Integral to the enclosure 110 is a pressure release vent 120 that mitigates high-pressure build-up by releasing a portion of the gases. The system features a condenser system 130 with a maze-like structure 132 that redirects gases to enhance heat transfer and condensation. Further a dual-part condenser configuration 140 includes a heat dissipation unit 142 and a cold plate 144 for efficient gas interaction.

Description

SYSTEM FOR GAS CONDENSATION AND CONTAINMENT IN LI-ION BATTERYTHERMAL RUNAWAYFIELD OF THE INVENTION

[0001] The present invention generally relates to battery safety and thermal management systems, and more particularly to a system for gas condensation and containment in Li-ion battery thermal runaway, specifically addressing the condensation and containment of gases released during thermal runaway of Li-ion cells.BACKGROUND

[0002] Lithium-ion (Li-ion) batteries are integral to modem technology, powering devices from electric vehicles to consumer electronics due to their superior energy density and longevity. Despite these advantages, Li-ion batteries are susceptible to thermal runaway, a hazardous condition where escalating temperatures lead to the release of hot gases, smoke, and potentially catastrophic explosions. This phenomenon poses significant safety risks, particularly in densely packed battery systems.

[0003] Current safety measures in Li-ion battery systems primarily focus on explosion prevention by incorporating venting mechanisms within the battery enclosures. These vents allow the rapid escape of gases generated during thermal runaway, thereby reducing the risk of pressure buildup and subsequent explosions. However, this venting approach inadvertently exposes users to harmful gases such as carbon monoxide and hydrogen fluoride, which are released during the thermal runaway process. These emissions can lead to severe health issues, including respiratory distress and chemical poisoning.

[0004] The existing solutions, while effective in mitigating explosion risks, fall short in addressing the critical issue of user exposure to toxic gases. The reliance on venting as a primary safety measure does not provide a comprehensive solution to the dual challenges of explosion prevention and user protection from harmful emissions. The lack of a mechanism to contain and neutralize these gases highlights a significant gap in current battery safety technologies.

[0005] Given these deficiencies, there is a clear and urgent need for a system that not only prevents explosions but also effectively contains and condenses the gases released during thermal runaway. Further there is need for a solution that enhances safety by preventing user exposure to toxic emissions while maintaining the structural integrity of the battery system.OBJECTS OF THE INVENTION

[0006] The object of the invention is to provide a robust enclosure connected to battery cell vents, designed to capture and contain gases released from the cells, thereby preventing their escape into the environment and enhancing safety.

[0007] Another object of the invention is to incorporate a pressure release vent within the enclosure, which functions to release gases in the event of high-pressure build-up, thus mitigating the risk of explosion within the battery pack.

[0008] Yet another object of the invention is to introduce an advanced condenser system that effectively cools and condenses hot gases into a liquid state, utilizing a maze-like structure to facilitate efficient heat transfer and condensation.

[0009] A further object of the invention is to offer a dual -part condenser configuration, allowing for the separation of the condenser into a heat dissipation unit and a cold plate for gas interaction, thereby enhancing the efficiency of the cooling process.

[0010] An additional object of the invention is to integrate the system with existing battery pack cooling systems, such as liquid or forced air cooling, to improve overall thermal management and maintain safe operating temperatures during thermal events.

[0011] Moreover, an object of the invention is to enhance safety by containing and condensing gases, thereby preventing explosions and exposure to toxic gases, significantly improving user safety.

[0012] Another object of the invention is to ensure efficient thermal management by integrating with existing cooling systems, thus enhancing the overall efficiency of the thermal management process.

[0013] Yet another object of the invention is to provide scalability and adaptability, allowing the design to be suitable for various sizes and configurations of battery packs, making it applicable to a wide range of applications from consumer electronics to large-scale energy storage systems.SUMMARY

[0014] This summary is provided to introduce concepts related to a system for gas condensation and containment during a thermal runaway event. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in limiting the scope of the claimed subject matter.

[0015] Embodiments of the present invention provide a system for gas condensation and containment in a lithium-ion battery thermal runaway scenario. The system comprises anenclosure connected to battery cell vents, configured to capture gases released during thermal runaway. The enclosure includes a pressure release vent that releases gases upon high-pressure build-up, ensuring safety by preventing potential explosions. A condenser system is mounted within the enclosure, featuring a maze-like structure that redirects gases multiple times to facilitate cooling and condensation. Additionally, a heat dissipation mechanism is operatively connected to the condenser system, configured to dissipate heat extracted from the gases. The condenser system comprises an integrated condenser and a split condenser, with the split condenser including a heat dissipation unit and a cold plate for direct gas interaction. The heat dissipation mechanism utilizes a liquid coolant or forced air cooling to maintain the system within safe operating temperatures.

[0016] The advantages offered by this embodiment include enhanced safety and efficient thermal management. By capturing and condensing gases within the enclosure, the system prevents explosions and exposure to toxic gases, significantly improving user safety. The integration of the heat dissipation mechanism ensures that the battery pack remains within safe operating temperatures, even during a thermal runaway event, thereby enhancing the overall efficiency of the thermal management process.

[0017] In accordance with an embodiment of the present invention, the enclosure is constructed from a durable material capable of withstanding high temperatures and pressures, ensuring airtight containment of gases. Additionally, the pressure release vent is strategically placed to manage high-pressure situations by releasing gases to prevent explosions. The mazelike structure of the condenser system is made from materials with high thermal conductivity, such as aluminum or copper, to enhance heat transfer and condensation efficiency. The heat dissipation mechanism includes a series of channels or pipes for circulating the liquid coolant in thermal contact with the condenser surfaces. Furthermore, the forced air cooling employs fans or blowers strategically placed to ensure optimal airflow and cooling efficiency. The enclosure is integrated with the battery's thermal management device, such as a forced air convection system or a liquid / oil cooling system, for rapid heat dissipation. The condensed liquid resulting from the cooled and condensed gases is collected at the bottom of the enclosure for safe containment.

[0018] In accordance with another embodiment of the present invention, a method for managing thermal runaway in a lithium-ion battery pack is provided. The method comprises capturing gases released from the battery pack during thermal runaway in an enclosure connected to the battery pack vents. The captured gases are cooled and condensed within a condenser system located in the enclosure. The gases are redirected multiple times through amaze-like structure within the condenser system to facilitate heat transfer and condensation. The heat extracted from the gases is dissipated using a thermal management device, such as a forced air convection system or a liquid / oil cooling system. The condensed liquid is contained within the enclosure to prevent environmental contamination.BRIEF DESCRIPTION OF DRAWINGS

[0019] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.

[0020] Fig. 1 illustrates a system drawing, in accordance with an exemplary embodiment of the present disclosure;

[0021] Fig. 2 illustrates an exploded view, in accordance with the present disclosure; and

[0022] Fig. 3 illustrates a part of the system, in accordance with the present disclosure.DETAILED DESCRIPTION

[0023] The present invention is subsequently described herein using various embodiments with reference to the accompanying drawing, wherein the reference numerals utilized in the accompanying drawing correspond to the similar elements throughout the description. While the present invention is illustratively described herein by way of example using embodiments and accompanying drawings, those skilled in the art will acknowledge that the invention is not limited to the described embodiments or drawings and is not intended to represent the scale of the different components. Furthermore, certain components that may constitute a part of the invention might not be depicted in specific figures for the purpose of simplified illustration, and such omissions do not restrict the outlined embodiments in any manner. It should be comprehended that the drawings and the detailed description provided are not intended to limit the invention to the particular disclosed form, but instead, the invention is intended to encompass all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claim. Throughout this description, the term 'may' is used in a permissive sense, indicating the potential to, rather than in a mandatory sense, indicating a requirement. Additionally, the words 'a' or 'an' signify at least one, and the word 'plurality' signifies 'one or more' unless otherwise specified. Moreover, the terminology and phraseology employed herein are solely for descriptive purposes and should not be construed as limiting in scope. Terms such as 'including', 'comprising', 'having', 'containing', or'involving', and their variations, are intended to be broad and encompass the listed subject matter thereafter, as well as equivalents and additional subject matter not explicitly mentioned, and should not be interpreted as excluding other additives, components, integers, or steps. Similarly, the term 'comprising' is considered synonymous with the terms 'including' or 'containing' for applicable legal purposes.

[0024] The present invention relates to a system designed for gas condensation and containment during thermal runaway events in lithium-ion (Li-ion) battery packs. The system is engineered to address the critical safety concerns associated with the release of gases during such events, providing a comprehensive solution that captures, cools, and contains these gases. The invention comprises an enclosure connected to the battery cell vents, a condenser system for cooling and condensing the gases, and a heat dissipation mechanism to manage the extracted heat. This system is adaptable to various battery configurations and operational requirements, ensuring enhanced safety and efficient thermal management.

[0025] A key aspect of the invention is the robust enclosure, which is connected to the battery cell vents to capture gases released during thermal runaway. The enclosure is equipped with a pressure release vent to manage high-pressure situations, thereby preventing potential explosions. The condenser system, integral to the invention, employs a maze-like structure to slow down the gases, facilitating effective heat transfer and condensation. This system may include an integrated condenser mounted directly inside the enclosure or a split condenser configuration, where one part dissipates heat to the environment and the other interacts with the gases.

[0026] The invention further incorporates a heat dissipation mechanism that utilizes existing thermal management systems, such as liquid cooling or forced air cooling, to dissipate the heat extracted from the gases. This integration with existing systems enhances the overall efficiency of the thermal management process, ensuring that the battery pack remains within safe operating temperatures. The system's design allows for scalability and adaptability, making it suitable for a wide range of applications, from consumer electronics to large-scale energy storage systems.

[0027] This present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description below:

[0028] System 100

[0029] Enclosure 110

[0030] Pressure release vent 120

[0031] Condenser 130

[0032] Dual-part condenser 140

[0033] Portion of the gases 112

[0034] Maze-like structure 132

[0035] Heat dissipation unit 142

[0036] Cold plate 144

[0037] Cell Stack 150

[0038] Thermal Connector 160

[0039] Outer Enclosure 115

[0040] Gas direction path 114

[0041] Inlet connector 116

[0042] Referring to Fig. 1, illustrates a system 100, according to some embodiments of the present disclosure. In some embodiments, the system 100 may include a condenser system 130 integrated within an enclosure 110 or a dual-part condenser configuration 140 operationally connected / integrated with the enclosure 110. The system 100 may also include the enclosure 110 configured to connect to vents via the inlet connector 116 of a lithium-ion battery pack, the enclosure 110 designed to capture. The system 100 may also include a pressure release vent 120 integrated within the enclosure 110, the pressure release vent 120 configured to release a portion of the gases 112 in the event of a high-pressure build-up.

[0043] In some embodiments, the enclosure 110 may include gases 112 released during a thermal runaway event. The condenser system 130 may include a maze-like structure 132 for redirecting gases multiple times to facilitate heat transfer and condensation. In another aspect the dual-part condenser configuration 140 may include a heat dissipation unit 142 and a cold plate 144 for gas interaction. The condenser system 130 may be configured to cool and condense the captured gases into a liquid state, reducing their pressure and temperature. The system 100 may be adapted to integrate with existing battery pack cooling systems for enhanced thermal management.

[0044] In another exemplary aspect the system 100 comprises a robust enclosure connected to the battery cell vents, designed to capture gases released during thermal runaway events. The enclosure is depicted as a sealed unit, ensuring that gases are effectively contained. The pressure release vent is integrated into the enclosure, allowing for controlled release of gases to prevent excessive pressure build-up, thereby mitigating the risk of explosion.

[0045] The condenser system is shown within the enclosure, featuring a maze-like structure that facilitates the cooling and condensation of gases. This structure is designed toredirect gases multiple times, allowing for extended interaction with the condenser surfaces. The condenser may be configured as an integrated unit within the enclosure or as a split system, with one part dissipating heat to the environment and the other part, a cold plate, interacting directly with the gases.

[0046] In one embodiment of the invention, the enclosure acts as a heat sink, mounted directly on top of the cell stack. This configuration includes multiple redirections for gases, slowing them down and allowing additional fins to extract heat. The heat is then dissipated through natural convection, making this embodiment suitable for applications with lower thermal management requirements.

[0047] Additionally, the system may be integrated with existing thermal management devices, such as forced air convection or liquid / oil cooling systems, for applications with higher thermal management needs. This integration allows for rapid heat dissipation, ensuring the system can handle more extreme conditions effectively. The use of existing cooling systems enhances the overall efficiency of the thermal management process, maintaining safe operating temperatures for the battery pack.

[0048] The system's design is adaptable, allowing for scalability across various battery configurations and operational requirements. This adaptability makes it suitable for a wide range of applications, from consumer electronics to large-scale energy storage systems. The invention's novel approach to gas containment and condensation significantly enhances safety by preventing explosions and exposure to toxic gases, while also improving thermal management efficiency.

[0049] Fig. 2 illustrates an exploded view of the system for gas condensation and containment in a lithium-ion battery thermal runaway scenario. The figure depicts the key components, including the cell stack 150, container enclosure 110, condenser 130 or 140, and heat dissipation system 142. The cell stack is shown as a series of aligned battery cells, each equipped with vents 116 for gas release during thermal runaway events. The container enclosure 110 is designed to capture these gases, ensuring they are directed towards the condenser system 130 or 140.

[0050] The pressure release vent 120 is integrated into the container enclosure 110, providing a safety mechanism to release gases and reduce pressure in case of high-pressure build-up. This vent 120 is crucial for maintaining structural integrity and preventing potential explosions within the battery pack. The thermal connection path 114 between the condenser 130 and the battery thermal management system 142 is also depicted, highlighting the integration of the system with existing cooling mechanisms.

[0051] In another embodiment of the invention, the condenser system comprises a split configuration 140, with a thermal connector 160 and a cold plate 144. The thermal connector 160 is responsible for transferring heat to the surrounding environment, while the cold plate interacts directly with the gases, facilitating their condensation. This dual-part configuration enhances the efficiency of the gas cooling process, ensuring effective condensation and containment.

[0052] Additionally, the heat dissipation mechanism may utilize a liquid cooling system, where a coolant absorbs and carries away the heat extracted from the gases. This method is particularly effective for applications requiring rapid heat dissipation, ensuring the battery pack remains within safe operating temperatures. Alternatively, forced air cooling can be employed, using fans or blowers to circulate air and remove heat from the system.

[0053] The system's design allows for various implementation options, catering to different thermal management requirements. For lower requirements, the enclosure itself can perform all three functionalities, acting as a heat sink with multiple redirections for gases and additional fins for heat extraction. For higher requirements, the system can be integrated with the battery's existing thermal management device, such as a forced air convection or liquid / oil cooling system, for enhanced heat dissipation.

[0054] The invention's adaptability and scalability make it suitable for a wide range of applications, from consumer electronics to large-scale energy storage systems. By effectively containing and condensing gases, the system significantly enhances safety, preventing explosions and exposure to toxic gases, while also improving the overall efficiency of thermal management.

[0055] Fig. 3 illustrates a part of the system for gas condensation and containment in a lithium-ion battery thermal runaway scenario. The figure depicts the outer enclosure 115 which is part of the enclosure 110, which is integral to capturing gases released from the battery cells. The enclosure 110 is shown with inlets connecting 116 to the cells, ensuring that gases are directed into the system for processing. The gas redirection paths 114 within the enclosure 110 are designed to guide the gases through a controlled pathway, facilitating effective interaction with the condenser system.

[0056] The pressure release vent outlet 120 is depicted on the enclosure 110, providing a critical safety feature. This vent is designed to release gases in the event of high-pressure buildup, thereby preventing potential structural failure or explosion within the battery pack. The strategic placement of the vent ensures that pressure is managed effectively, maintaining the integrity of the system.

[0057] In one embodiment of the invention, the gas redirection paths within the enclosure are configured to slow down the gases, allowing for extended interaction with the condenser surfaces. This design enhances the efficiency of the heat transfer process, ensuring that the gases are cooled and condensed effectively. The materials used for the enclosure and redirection paths may include heat-resistant alloys or composites, providing durability and thermal stability.

[0058] Additionally, the system may incorporate a split condenser configuration, where the heat dissipation unit 142 is positioned externally to the enclosure 110. This setup allows for efficient heat transfer to the surrounding environment, while the cold plate 144 within the enclosure interacts directly with the gases. The use of advanced materials for the cold plate, such as high-conductivity metals, enhances the condensation process.

[0059] The system's adaptability allows for integration with existing thermal management devices, such as liquid cooling systems or forced air convection. This integration ensures rapid heat dissipation, maintaining safe operating temperatures for the battery pack. The design is scalable, making it suitable for various applications, from consumer electronics to large-scale energy storage systems.

[0060] In accordance with yet another embodiment of the present invention, the enclosure may be equipped with additional fins or heat sinks to further enhance heat dissipation. These components can be manufactured using extrusion or casting techniques, utilizing materials with high thermal conductivity. The inclusion of these features ensures that the system can handle more extreme thermal conditions, providing a robust solution for gas containment and condensation.

[0061] The system's adaptability is further exemplified by its ability to accommodate various battery pack configurations and sizes, making it suitable for a wide range of applications. In one embodiment of the present invention, the system may be configured to operate in conjunction with a battery management system (BMS) that monitors the thermal conditions and activates the gas containment and condensation process upon detecting a thermal runaway event. This integration ensures that the system responds promptly to any safety threats, thereby enhancing the overall reliability and safety of the battery pack.

[0062] Another embodiment of the present invention may include the use of advanced materials for the condenser surfaces, such as phase change materials (PCMs) or thermally conductive polymers, which can further improve the efficiency of the heat transfer and condensation process. These materials may be selected based on their thermal properties andcompatibility with the battery pack environment, ensuring optimal performance under various operating conditions.

[0063] The invention's benefits are underscored by its ability to significantly enhance safety by preventing explosions and exposure to toxic gases during thermal runaway events. The technical features that enable these advantages include the robust enclosure with a pressure release vent, the advanced condenser system with a maze-like structure, and the integration with existing thermal management systems. These features collectively ensure that the battery pack remains within safe operating temperatures, thereby improving the overall efficiency of the thermal management process and extending the lifespan of the battery pack. The invention's scalability and adaptability make it a versatile solution for diverse applications, from consumer electronics to large-scale energy storage systems, providing a comprehensive approach to managing thermal runaway events in lithium-ion battery packs.

[0064] In accordance with another exemplary embodiment discloses a system 100 for gas condensation and containment in Li-ion battery thermal runaway as illustrated in Fig. 1 to Fig. 3. The system 100 as disclosed comprises a plurality of cell stack 150. Further the plurality of cell stack 150 may be operationally connected with an enclosure 110. The enclosure 110, may be configured to capture thermal runway, or gas condensation, released from the plurality of cell stack 150.

[0065] Further the enclosure 110 in aspect may be operationally integrated with a condenser 130. The condenser 130, may be integrated within the enclosure 110 such that thermal runway, or gas from the cell stack 150, is channeled or directed via the gas direction path 114 into the condenser 130. Further an inlet connector 116, provided on the enclosure 110, enables the flow of the gas between the cell stack 150 and the enclosure 110.

[0066] The condenser 130, may be provided with maze-like structure 132. The maze-like structure 132, enables heat extraction from the gas, as gas flows through the maze structure 132. Further the heat extracted from the maze-like structure 132, is transferred to an outer enclosure 115. The outer enclosure 115 enables heat dissipation to the environment or surrounding.

[0067] Further a thermal connector 160 may be configured to transfer the heat to a cold plate 144, extracted from the outer enclosure 115. The cold plate 144, may be integrated with a heat dissipation unit 142. The heat dissipation unit 142, may be positioned below the cell stack 150, or above the cell stack 150, or at least on two sides of the cell stack 150.

[0068] In another aspect the enclosure 110, may be a split condenser 140. The split condenser 140, one for dissipating heat to the surrounding environment and the other (cold plate) for interacting with the gases.

[0069] The foregoing objects of the invention are accomplished, and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiment. Detailed descriptions of the preferred embodiment are provided herein; however, it is to be understood that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure, or matter. The embodiments of the invention as described above and the methods disclosed herein will suggest further modification and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the scope of the invention.

Claims

We Claim:

1. A system 100 for gas condensation and containment in Li-ion battery thermal runaway, comprising: an enclosure 110 configured to connect to vents of a cell stack 150, the enclosure 110 is configured to capture and contain gases released during a thermal runaway event; a pressure release vent 120 integrated within the enclosure 110, the pressure release vent 120 is configured to release a portion of the gases in the event of a high-pressure build-up; and a condenser system 130 or a dual-part condenser configuration 140 operationally integrated with the enclosure 110, wherein the condenser system 130 comprising a mazelike structure 132 for redirecting gases multiple times to facilitate heat transfer and condensation; wherein the dual-part condenser configuration 140, includes a heat dissipation unit 142 and a cold plate 144 for gas interaction.

2. The system as claimed in claim 1, wherein the pressure release vent 120 is configured to release gases from the battery enclosure to mitigate the risk of explosion.

3. The system as claimed in claim 1, wherein the maze-like structure 132 of the condenser system 130 enables extension of the interaction time of gases with condenser surfaces, enhancing heat transfer efficiency.

4. The system as claimed in claim 1, wherein the heat dissipation unit 142 of the dual -part condenser configuration 140 is configured to dissipate heat to the surrounding environment.

5. The system as claimed in claim 1, wherein the cold plate 144 of the dual-part condenser configuration 140 is configured to interact directly with the gases to enhance condensation efficiency.

6. The system as claimed in claim 1, wherein the enclosure 110 is configured to perform as a heat sink mounted directly on top of the cell stack 150 for lower thermal management requirements.

7. The system as claimed in claim 6, wherein the enclosure includes additional fins to extract heat from the gases, dissipating it through natural convection.

8. A method for gas condensation and containment in Li-ion battery thermal runaway, comprising:capturing gases released during a thermal runaway event within an enclosure connected to battery cell vents; releasing a portion of the gases through a pressure release vent in the event of a high-pressure build-up; redirecting the captured gases multiple times through a maze-like structure within a condenser system to facilitate heat transfer and condensation; cooling and condensing the gases into a liquid state using a dual -part condenser configuration, including a heat dissipation unit and a cold plate for gas interaction; and integrating the system with existing battery pack cooling systems to enhance thermal management.Date this 17thDay of December, 2024Samendra PatilIN / PA 5092Agent for the Applicant

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