Battery Module Barrier With Phase Change Material for Runaway Isolation
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Solution Overview
Problem
Thermal runaway and propagation between battery cells in a battery module can lead to catastrophic failures, posing risks in applications such as electric vehicles and energy storage systems.
Innovation Solution
Incorporation of a barrier with a phase change material, such as water, and a rigid member to absorb heat and prevent thermal runaway between cell blocks, along with a module housing to contain the phase change material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are arranged in adjacent cell blocks without barriers, then device complexity is reduced and manufacturing is simpler, but thermal runaway can propagate between cell blocks causing catastrophic failure
Solution Approach 1:
The cell assembly is divided into multiple cell blocks with barriers positioned between adjacent blocks. This segmentation isolates thermal events to specific blocks, preventing propagation while maintaining manageable structural complexity through modular barrier design.
Solution Approach 2:
Barriers serve as intermediary components between adjacent cell blocks. These barriers include phase change materials that actively intervene in heat transfer, absorbing thermal energy and preventing direct thermal coupling between blocks, thus blocking runaway propagation.
2Reliability
If barriers with phase change material are inserted between cell blocks, then thermal runaway propagation is prevented, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The barrier structure employs nested design where the rigid member housing contains the phase change material, which is further enclosed in a flexible pouch. This nested arrangement consolidates multiple protective functions into a single integrated component that can be pre-assembled and then easily installed between cell blocks.
Solution Approach 2:
The barrier design utilizes phase change material that changes physical state (parameter) in response to temperature. This passive response mechanism eliminates the need for active control systems, sensors, or complex assembly procedures, thereby simplifying manufacturing while maintaining effective thermal runaway prevention.
3Reliability
If volume of phase change material is increased to improve thermal protection, then thermal runaway delay is enhanced, but space occupancy and device dimensions increase
Solution Approach 1:
The barrier combines rigid structural material with phase change material in a composite construction. The rigid member provides mechanical strength and spatial definition with minimal volume, while the phase change material is contained within a flexible pouch that conforms to the available space, maximizing protective function without excessive volume occupation.
Solution Approach 2:
The phase change material is strategically positioned in the flexible pouch at locations where thermal propagation is most likely to occur between cell blocks. This localized placement ensures effective thermal protection is provided at critical interfaces without distributing material volume throughout the entire barrier structure.
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 barrier effectively delays or prevents thermal runaway, enhancing safety and reducing the risk of fire or explosion in battery modules and packs.
Implementation Method 1
The barrier may include a phase change material including water, and a rigid member accommodating the phase change material
Implementation Method 2
Heat, gas, or flames generated in one battery cell among the plurality of battery cells may propagate to other battery cells in adjacent cell blocks, resulting in thermal runaway or thermal propagation
Data Source
AI summary
A battery module includes: a cell assembly including a plurality of cell blocks respectively including a plurality of battery cells, and a barrier disposed between the plurality of cell blocks; and a module housing accommodating the cell assembly. The barrier may include a phase change material including water, and a rigid member accommodating the phase change material, and the volume of water relative to a capacity of one of the plurality of cell blocks may be 1.000 cc/Ah or more.