Battery Module Busbars with Phase-Change Powder for Thermal Runaway
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Solution Overview
Problem
Existing cooling devices fail to effectively mitigate thermal runaway propagation in battery packs without increasing pressure or compromising weight and size, thus posing a risk of thermal runaway and explosion.
Innovation Solution
A phase-change metallic powder is applied on busbars within the battery module, changing phase at high temperatures to limit thermal convection and conduction, preventing thermal runaway propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cooling devices are added to mitigate thermal runaway propagation, then thermal safety is improved, but device complexity and weight increase
Solution Approach 1:
The invention extracts the cooling function from a separate active cooling device and integrates it into the battery module structure itself through phase change materials placed in thermal contact with battery cells. This eliminates the need for external cooling devices while maintaining thermal safety.
Solution Approach 2:
The phase change materials automatically absorb excess heat during thermal runaway events without requiring external control systems, power sources, or active intervention. The material self-regulates temperature by changing phase, providing passive thermal management.
2Temperature
If phase change materials are used to limit thermal runaway propagation, then thermal convection is limited, but pressure increase occurs
Solution Approach 1:
The invention utilizes phase transitions of metal powders (melting and solidification) to absorb and release thermal energy. The phase change occurs at controlled temperatures, allowing the material to limit thermal convection while the solid structure maintains mechanical stability and limits pressure buildup.
Solution Approach 2:
The invention employs composite structures combining phase change metal powders with supporting matrices or containers. This composite approach provides both the thermal management function through phase change and the mechanical strength needed to contain pressure increases during thermal events.
3Temperature
If phase change metal powder is applied on busbars, then thermal conduction is limited, but manufacturing complexity increases
Solution Approach 1:
The invention merges the thermal management function with the existing busbar structure by applying phase change metal powder directly onto the busbars. This combines two functions (electrical connection and thermal management) into a single integrated component, simplifying the overall system.
Solution Approach 2:
The phase change metal powder can be applied as a simple coating or layer that is easily manufactured and integrated during the battery assembly process. The material itself is relatively simple and can be applied using straightforward techniques, reducing manufacturing 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 solution effectively reduces thermal runaway propagation by limiting temperature and pressure, ensuring safer operation without adding weight or size, and preventing potential explosions.
Implementation Method 1
at least one phase-change metallic powder, placed in at least one area intended for the passage of hot gases released by one of the accumulators during a thermal runaway, the powder being adapted to change phase in the area and thus limit the thermal convection of the hot gases released
Data Source
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AI summary
Battery module with at least one accumulator comprising a phase-change metal powder to limit the propagation of thermal runaway and the associated increase in pressure. The invention relates to a battery module (M) comprising at least one phase-change metal powder (10), placed in at least one zone intended for the passage of hot gases released by one of the accumulators during thermal runaway, the powder being adapted to change phase in the zone and thus limit the thermal convection of the released hot gases.