Battery Pack Thermal Barrier Baffles for Cascade Event Containment
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Solution Overview
Problem
Existing thermal barriers in traction battery packs face challenges in effectively managing thermal energy and preventing cascading thermal events between battery cell groups.
Innovation Solution
A thermal barrier assembly comprising a first and second outer shell with an insulative material sandwiched between them, and a plurality of baffles that restrict the movement of the insulative material within the insulation cavity, thereby compartmentalizing the thermal barrier and directing vented gases and debris away from other battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal barrier assembly is used to separate battery cell groups, then thermal energy management is improved, but device complexity increases due to multiple components (outer shells, insulative material, baffles)
Solution Approach 1:
The thermal barrier assembly is segmented into distinct functional components: outer shells provide structural containment, insulative material provides thermal isolation, and baffles provide internal compartmentalization. This segmentation allows each component to be optimized for its specific function while collectively achieving reliable thermal energy management.
Solution Approach 2:
The insulative material is nested within the insulation cavity formed by the outer shells, and the baffles are nested within the insulation cavity to compartmentalize the insulative material. This nested arrangement achieves complex thermal management functionality while maintaining a compact overall structure.
2Stability of the object's composition
If baffles are added to restrict insulative material movement, then thermal barrier stability is improved, but manufacturing complexity increases
Solution Approach 1:
The baffles are pre-formed as integral parts of the outer shells or as separate components ready for installation. This preliminary preparation allows for easier assembly during manufacturing, as the baffles can be pre-positioned or pre-attached to provide immediate structural guidance for the insulative material.
Solution Approach 2:
The baffles provide localized structural features at specific positions within the insulation cavity where insulative material movement needs to be restricted. Rather than requiring a completely rigid structure throughout, the baffles provide stability only where needed, maintaining ease of manufacture while achieving compositional stability.
3Reliability
If the insulation cavity is compartmentalized using baffles, then thermal energy containment is improved, but loss of substance increases due to potential gaps between components
Solution Approach 1:
The insulation cavity is segmented into multiple compartments by the baffles, creating a labyrinthine path for any vented gases or debris. This segmentation improves thermal energy containment by creating multiple barriers, while the overlapping outer rims ensure that the segmentation does not create through-gaps for substance loss.
Solution Approach 2:
The baffles act as intermediary structures within the insulation cavity, providing thermal barriers and directing flow paths without creating direct gaps between the outer shells. The overlapping outer rims serve as intermediary sealing elements that prevent substance loss while allowing the internal compartmentalization to function.
4Reliability
If outer rims overlap to seal the insulation cavity, then thermal isolation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The first and second outer shells are merged at their overlapping rims to form a continuous sealed structure. This merging provides robust thermal isolation by eliminating gaps at the junction, while the overlapping design is forgiving of minor alignment variations compared to a perfectly fitted joint.
Solution Approach 2:
The outer shells are designed with flexible overlapping rims that can accommodate minor manufacturing variations and assembly tolerances. This flexibility allows the overlapping joints to maintain effective thermal isolation without requiring extremely high manufacturing precision, as the flexible nature of the overlapping structure compensates for small dimensional variations.
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 assembly effectively separates battery cell groups, contains and directs thermal energy and vented gases, preventing cascading thermal events and ensuring efficient thermal management within the traction battery pack.
Implementation Method 1
an insulative material sandwiched between the first outer shell and the second outer shell within the insulation cavity
Data Source
AI summary
A traction battery pack thermal barrier assembly includes a first outer shell; a second outer shell adjacent the first outer shell to define an insulation cavity; and an insulative material sandwiched between the first outer shell and the second outer shell within the insulation cavity. Baffles extend into the insulation cavity and restrict movement of the insulative material within the insulation cavity.