Traction Battery Array Compartments for Thermal Propagation Mitigation

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Solution Overview

Problem

Existing traction battery packs face challenges in mitigating thermal propagation during battery thermal events, which can lead to cell damage and reduced performance.

Innovation Solution

The proposed battery array design includes an outer array housing, a cell stack, and a compartment with a non-conductive coolant that limits thermal propagation. The compartment is divided into a fluid-filled portion and an air gap portion, with a slotted plate establishing a physical interface between them, providing a venting path for battery vent byproducts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional battery array design is used, then the structure is simple, but thermal propagation between cells cannot be effectively mitigated during thermal events

Engineering Contradiction:

Improvethermal propagation mitigationVSAvoidbattery array structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The battery array is segmented into multiple compartments by partition walls, with each compartment containing a subset of battery cells. This segmentation isolates thermal events to specific compartments, preventing thermal propagation across the entire cell stack while maintaining a manageable structural complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A non-conductive coolant is introduced as an intermediary substance between the battery cells within each compartment. This coolant acts as a thermal barrier that limits heat transfer between cells during thermal events, thereby mitigating thermal propagation without requiring direct physical separation of all cells.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If coolant is used to mitigate thermal propagation, then thermal events are controlled, but electrical conductivity may cause safety issues

Engineering Contradiction:

Improvethermal event controlVSAvoidelectrical conductivity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The coolant is specifically selected to have non-conductive properties, changing the electrical conductivity parameter from conductive (harmful) to non-conductive (safe). This parameter change allows the coolant to perform its thermal management function without introducing electrical conductivity-related safety hazards.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system uses a composite approach by combining the coolant function (thermal management) with non-conductive material properties (electrical insulation). This composite material selection ensures that the coolant simultaneously provides thermal protection and electrical isolation, eliminating the harmful effect of electrical conductivity.

Inventive Principle:

Principle #40Composite materials

3Reliability

If a compartment structure is added to limit thermal propagation, then cell-to-cell heat transfer is prevented, but the device complexity increases

Engineering Contradiction:

Improvecell-to-cell heat transfer preventionVSAvoidcompartment structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The battery array is divided into multiple compartments using partition walls, creating a segmented structure that physically limits thermal propagation between cell groups. This segmentation approach prevents cell-to-cell heat transfer while maintaining structural organization through modular compartments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The partition walls serving as compartment boundaries are designed to perform multiple functions: providing structural support, defining compartment boundaries for thermal isolation, and potentially serving as mounting surfaces for other battery components. This multi-functionality reduces overall device complexity by combining multiple functions into single structural elements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This design effectively mitigates thermal propagation across the cell stack during battery thermal events, preventing cell-to-cell heat transfer and providing a dedicated venting path for vent byproducts, thus enhancing the safety and performance of the battery pack.

Implementation Method 1

a non-conductive coolant contained within the compartment and configured to limit thermal propagation across the cell stack during a battery thermal event

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

the air gap portion provides a venting path for venting battery vent byproducts during the battery thermal event

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250183412A1Systems and methods for mitigating thermal propagation within traction battery arrays

Publication Date: 2025.06.05 FORD GLOBAL TECH LLC

AI summary

Battery arrays are provided for traction battery packs. An exemplary battery array may include one or more internal compartments. Each compartment may contain a non-conductive coolant for mitigating or even preventing cell-to-cell thermal propagation. An air gap of the compartment may provide a venting path for venting battery vent byproducts during a battery thermal event.