Battery Module Thermal Barrier Venting Against Runaway Propagation

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Solution Overview

Problem

Current cooling or heat-dissipation strategies for battery modules or battery packs are insufficient to mitigate thermal runaway propagation between adjacent modules within a rechargeable energy storage system (RESS).

Innovation Solution

Incorporating a thermal barrier at the end portion of each battery module, external to the battery cell groups, which provides ventilation for a battery module experiencing thermal runaway and directs hot gases and/or particles away from adjacent modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If current cooling or heat-dissipation strategies (cooling plates) are used in battery modules, then thermal load regulation within individual cells and packs is improved, but thermal runaway propagation between adjacent modules cannot be mitigated

Engineering Contradiction:

Improvethermal load regulationVSAvoidthermal runaway propagation mitigation

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The battery system is divided into multiple battery modules, each equipped with its own independent thermal barrier and venting system. This segmentation isolates thermal runaway events to individual modules, preventing propagation to adjacent modules while maintaining effective cooling within each module.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A thermal barrier is introduced as an intermediary component between adjacent battery modules. This thermal barrier includes venting pathways that intercept and redirect hot gases and particulates generated during thermal runaway, preventing them from reaching adjacent modules while allowing pressure relief.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal barriers with venting pathways are added to battery modules, then thermal runaway propagation mitigation is improved, but device complexity increases

Engineering Contradiction:

Improvethermal runaway propagation mitigationVSAvoidbattery module structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The thermal barrier is designed to perform multiple functions simultaneously: it acts as a physical barrier to hot gases, provides structured venting pathways for pressure relief, and directs particulates away from adjacent modules. This multi-functionality reduces the need for additional separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Instead of trying to contain thermal runaway completely within the battery module, the design inverts the approach by providing controlled escape pathways that redirect harmful substances away from critical areas. The thermal barrier allows thermal runaway to occur safely within one module while protecting others.

Inventive Principle:

Principle #13The other way round (Inversion)

3Loss of energy

If cooling plates are disposed between battery packs and modules, then heat dissipation within modules is improved, but protection against external thermal runaway propagation is insufficient

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidexternal thermal runaway exposure

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The thermal barrier serves as an intermediary layer between battery modules, positioned to intercept hot gases and particulates from thermal runaway events. This intermediary structure protects adjacent modules from external thermal exposure while not interfering with the cooling plates' ability to dissipate heat within each module.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively relieves pressure from propagated battery cells, directs hot gases and/or particles outside the RESS, and prevents adjacent modules from exceeding thermal runaway propagation threshold temperatures.

Implementation Method 1

The gas pathway may vent the hot gas and/or particles, generated by the propagated battery cell, to an outside of the RESS

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Implementation Method 2

Hot gas and/or particles from the propagated battery cell may travel along a gas pathway to an outside of the RESS

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250038291A1Thermal runaway propagation mitigation system and method

Publication Date: 2025.01.30 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A rechargeable energy storage system (RESS) for a vehicle having thermal runaway propagation mitigation includes at least two battery modules disposed within the RESS. Each battery module includes a plurality of battery cell groups, and a thermal barrier disposed at an end portion of each battery module. Each thermal barrier extends along a width of the end portion of each battery module, and includes a plurality of openings having at least one opening aligned with each of the plurality of battery cell groups of each battery module, and a relief portion adjacent to each of the plurality of openings. The relief portions prevent hot gas and/or particles from venting through an opening adjacent to the relief portion when in a closed position, and allows the hot gas and/or particles to vent through the opening adjacent to the relief portion when in an open position.