Battery Pack Barrier Assembly for Vent Byproduct Sealing
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Solution Overview
Problem
Existing traction battery packs face challenges in effectively blocking vent byproducts from moving into sensitive areas, such as those containing electronics, during thermal events.
Innovation Solution
A barrier assembly is introduced within the battery pack enclosure, comprising a container with expandable foam. The foam is delivered through passages in the container to interfaces between the container and battery components, bonding the container to the battery array and the enclosure surface, thereby blocking the flow of vent byproducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a barrier assembly is introduced to block vent byproducts, then protection of electronic components is improved, but device complexity increases
Solution Approach 1:
The barrier assembly is segmented into a container portion and a foam portion, allowing each component to perform its specific function independently. The container provides structural support and positioning, while the foam provides sealing and bonding, thereby achieving effective protection without excessive complexity.
Solution Approach 2:
The foam is nested within the container, creating a compact integrated structure. This nesting approach allows the barrier assembly to achieve complex protective functionality while maintaining a space-efficient design that minimizes overall device complexity.
2Strength
If expandable foam is used to seal interfaces, then bonding strength is improved, but manufacturing complexity increases
Solution Approach 1:
The foam is pre-positioned within the container before final assembly with the battery array. This preliminary action allows the foam to be properly placed and configured before it expands and bonds the components together, simplifying the manufacturing process while ensuring strong bonding.
Solution Approach 2:
The expandable foam serves multiple functions automatically: it bonds the container to the battery array and enclosure surface, seals interfaces, and provides thermal insulation. This self-service capability reduces the need for additional manufacturing steps and components, thereby improving ease of manufacture despite the complex bonding requirements.
3Reliability
If the container is bonded to multiple surfaces, then sealing effectiveness is improved, but device complexity increases
Solution Approach 1:
The foam portion is designed to perform multiple sealing and bonding functions simultaneously. It bonds the container to both the battery array and the enclosure surface, seals multiple interfaces, and provides thermal insulation. This multi-functionality achieves comprehensive sealing effectiveness without requiring separate components for each function, thereby managing device complexity.
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 assembly effectively seals off vent byproducts from reaching sensitive electronic components, enhancing the safety and reliability of the battery pack during thermal events.
Implementation Method 1
introducing an expandable foam into the container; and delivering the expandable foam through the container to at least one interface between the container and the at least one component
Implementation Method 2
bonding the container to the battery array and the enclosure surface, thereby blocking the flow of vent byproducts
Implementation Method 3
enhancing the safety and reliability of the battery pack during thermal events
Data Source
AI summary
A battery pack system includes a battery pack enclosure housing a battery array, and a barrier assembly within the enclosure. The barrier assembly includes a container and an expandable foam contained within the container. A battery pack barrier providing method, includes positioning a container within an interior of a battery pack enclosure adjacent to at least one component within the interior, introducing an expandable foam into the container, and delivering the expandable foam through the container to at least one interface between the container and the at least one component.