Battery Array Foam Barriers for Thermal Propagation Control
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Solution Overview
Problem
Existing electrified vehicle traction battery packs face challenges in mitigating thermal propagation within battery arrays, which can lead to battery thermal events and affect performance and safety.
Innovation Solution
The implementation of a thermal barrier foam system within the battery array, comprising foam blocks attached to hook structures of the bus bar module, which fill void spaces to prevent thermal propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If thermal barrier foam system is implemented to fill void spaces between battery cells and bus bar modules, then thermal propagation is mitigated and thermal insulation is enhanced, but device complexity and manufacturing complexity increase due to additional components and assembly steps
Solution Approach 1:
The foam blocks are nested within the battery array structure, filling void spaces between battery cells and bus bar modules. The hook structures are integrated as integral subcomponents of the bus bar module frame, creating a nested configuration where the foam system is embedded within the existing structural framework without requiring separate mounting systems.
Solution Approach 2:
The hook structures are merged with the bus bar module frame as integral subcomponents, combining the foam attachment function with the existing structural element. This merging eliminates the need for separate attachment mechanisms and integrates the thermal barrier system into the bus bar module design.
2Object-affected harmful factors
If foam blocks are attached to hook structures of bus bar module, then thermal insulation between battery cells and bus bar modules is improved, but manufacturing precision and assembly difficulty increase due to precise positioning requirements
Solution Approach 1:
The hook structures are pre-formed as integral subcomponents of the bus bar module frame during the bus bar module manufacturing process. This preliminary formation of attachment structures eliminates the need for precise field assembly operations and ensures consistent positioning of foam blocks relative to the bus bar module frame.
Solution Approach 2:
The foam blocks are positioned specifically at locations where thermal propagation risk is highest - between battery cells and bus bar modules. The hook structures are strategically located at these critical thermal interfaces, providing targeted thermal insulation where it is most needed rather than uniform insulation throughout the entire battery array.
3Device complexity
If hook structures are designed as integral subcomponents of bus bar module frame, then device complexity is reduced and manufacturing is simplified, but attachment reliability and foam block security may be compromised
Solution Approach 1:
The bus bar module frame is constructed as a composite structure combining the electrical conductive material (for the bus bar function) with the foam attachment function integrated into the frame design. This composite approach allows the same structural element to serve multiple functions - electrical conduction and foam block attachment - without compromising either function.
Solution Approach 2:
The hook structures are nested within the bus bar module frame design as integral subcomponents. This nested configuration ensures that the attachment structures are firmly integrated into the frame structure, providing reliable foam block retention while maintaining the overall structural integrity of the bus bar module.
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 thermal barrier foam system effectively mitigates cell-to-cell and array-to-array thermal propagation, enhancing thermal insulation and reducing the risk of battery thermal events.
Implementation Method 1
The thermal barrier foam system effectively mitigates cell-to-cell and array-to-array thermal propagation, enhancing thermal insulation
Data Source
AI summary
Battery arrays are provided for traction battery packs. An exemplary battery array may include a thermal barrier foam system that includes one or more foam blocks arranged to fill void spaces within the battery array to mitigate cell-to-cell and/or array-to-array thermal propagation. The foam blocks may be secured to hook structures of a bus bar module of the battery array. The hook structures can be integrated as part of the bus bar module or part of a separate structure that is attachable to the bus bar module.