Battery Assembly with Integrated Heater and Refractory Panels
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Solution Overview
Problem
Commercial Off-The-Shelf (COTS) lithium-ion battery cells face challenges in extreme low temperatures and are susceptible to thermal runaway, which can lead to chain reactions in multi-cell battery arrays, causing damage and safety issues.
Innovation Solution
A modular battery assembly design featuring a housing with recessed bus strips acting as fuses, a built-in heater, and refractory panels with weakened regions for venting, along with a heat spreader plate and gap filler pads for thermal management, to prevent failure propagation and facilitate operation in low temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If COTS lithium-ion battery cells are used in extreme low temperature conditions, then the battery assembly can operate in a wider temperature range, but the cells require pre-heating which adds complexity and reduces efficiency
Solution Approach 1:
The heating function is merged with the existing battery cell structure by integrating heating elements directly into the cell assembly. The connection branches that electrically connect adjacent cells are configured to serve dual purposes: electrical conduction and heat generation through resistive heating when current flows through them during charging or discharging operations.
Solution Approach 2:
The battery cells heat themselves through their own operational current. When charge current flows through the cells during charging, or discharge current during operation, the electrical resistance of the cells and connection branches generates heat that warms the cells to optimal operating temperature, eliminating the need for external heating systems.
2Quantity of substance
If battery cells are arranged in a multi-cell battery array, then the energy capacity is increased, but thermal runaway in one cell can trigger chain reactions in other cells
Solution Approach 1:
The battery array is segmented into electrically isolated groups by incorporating fuse elements in the connection branches between adjacent cells. These fuse portions create electrical disconnection points that prevent current from flowing between cells, thereby stopping thermal runaway propagation while maintaining the high energy capacity of the multi-cell array.
Solution Approach 2:
The connection branches with fuse portions act as intermediary elements between adjacent battery cells. These intermediaries provide both electrical connection for normal operation and automatic disconnection through fuse blowing when thermal runaway occurs, serving as a protective barrier that isolates failing cells from the rest of the array.
3Reliability
If bus strips are placed close to battery cells for efficient electrical connection, then the electrical conductivity is improved, but they are exposed to material ejected from failing cells
Solution Approach 1:
The connection branches with fuse portions are nested within recesses formed in the housing structure. This nesting arrangement protects the electrical connection elements from exposure to ejected material during cell failure while maintaining close proximity to the battery cells for efficient electrical connection. The recesses create a protective cavity that shields the bus strips and connection elements.
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 solution effectively prevents thermal runaway propagation, ensures safe operation in low temperatures, and minimizes damage by dispersing heat and protecting adjacent cells from high temperatures.
Implementation Method 1
a heater and a heater spreader plate to facilitate operation in low temperatures
Implementation Method 2
The connection branches may comprise portions sized to form fuses
Implementation Method 3
a heat spreader plate and gap filler pads for thermal management, to prevent failure propagation and facilitate operation in low temperatures
Data Source
AI summary
A battery assembly may include bus strips located on one or more sides and displaced ends of battery cells. The battery assembly may comprise a heater. The battery assembly may comprise one or more refractory panels. A refractory panel may comprise weakened regions corresponding to battery cells.