Battery Pack Aerosol Suppression for Thermal Runaway Mitigation
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Solution Overview
Problem
Electrified vehicle traction battery packs face thermal runaway issues during events like overcharging, overdischarging, or overheating, leading to heat propagation and potential battery damage, which existing technologies fail to effectively mitigate.
Innovation Solution
A thermal suppression system incorporating aerosol devices integrated into the battery array, featuring an aerosol ignition portion made of nitrocellulose and an aerosol generating portion made of potassium nitrate, which react to form an aerosol cloud to suppress heat propagation, activated by a thermal sensing device when temperature thresholds are exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal suppression systems are integrated into battery arrays, then thermal runaway mitigation is improved, but device complexity increases
Solution Approach 1:
The aerosol device merges multiple functions into a single integrated unit: the housing contains both the ignition portion (nitrocellulose) and generating portion (potassium nitrate), combining ignition system, propellant storage, and aerosol generation into one compact component that is directly integrated into the battery array structure
Solution Approach 2:
The aerosol device employs a nested structure where the ignition portion is contained within the housing, the generating portion is positioned within the same housing, and the entire aerosol device is integrated into the battery array support structure or spacer plates, creating multiple levels of containment and integration
2Object-affected harmful factors
If aerosol devices are integrated into battery arrays, then heat propagation suppression is improved, but manufacturing complexity increases
Solution Approach 1:
The aerosol device is segmented into distinct functional portions: the ignition portion (nitrocellulose) is separated from the generating portion (potassium nitrate), allowing each component to be manufactured and quality-tested independently before assembly into the final aerosol device
Solution Approach 2:
The aerosol device serves multiple functions simultaneously: it acts as a thermal suppression system, an aerosol generation device, and an integrated safety mechanism, while the housing serves both as a structural container and as part of the battery array support structure
3Reliability
If thermal suppression systems are activated, then thermal runaway mitigation is improved, but energy consumption increases
Solution Approach 1:
The aerosol device is designed to activate automatically through self-service mechanism: the ignition portion (nitrocellulose) spontaneously ignites when exposed to thermal runaway conditions, eliminating the need for external power sources, sensors, or control systems to trigger the thermal suppression response
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively mitigates thermal runaway by forming an aerosol cloud that cools the battery cells, preventing further heat escalation and reducing the risk of thermal propagation, thereby protecting the battery pack.
Implementation Method 1
an aerosol device that includes an aerosol ignition portion and an aerosol generating portion that is configured to react with the aerosol ignition portion
Implementation Method 2
forming an aerosol cloud that cools the battery cells, preventing further heat escalation
Data Source
AI summary
Battery thermal suppression systems may be provided for battery arrays and/or traction battery packs. Exemplary thermal suppression systems may include one or more aerosol devices that are adapted to release aerosol particles that may be distributed over and/or around battery cells/battery arrays during battery thermal events, thereby mitigating thermal propagation. The aerosol devices may be active or passive devices and can be implanted at the battery array level, the traction battery pack level, or both.