Battery Cell Module Layout for Thermal Runaway Containment
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Solution Overview
Problem
Existing battery designs suffer from poor space utilization and low power-to-weight ratios, particularly in aeronautical applications, and are prone to cascading thermal runaway failures due to inadequate thermal management.
Innovation Solution
A battery cell module comprising flat battery cells stacked with compressible aerogel and phase change materials (PCMs) for heat absorption, along with a circuit arrangement and separation layers for thermal and mechanical protection, allowing for efficient packing and reduced risk of thermal runaway propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cells are packed closely together to improve space utilization, then space utilization improves, but thermal runaway propagation risk increases
Solution Approach 1:
The patent introduces thermal insulation elements as intermediary components positioned between adjacent battery cells. These elements act as mediators that physically separate cells while maintaining compact packaging, thereby preventing direct thermal contact and blocking heat transfer paths during thermal runaway events.
Solution Approach 2:
The patent extracts and removes potential heat transfer paths by introducing thermal insulation barriers between cells. This extraction of thermal contact paths allows close cell packing while eliminating the harmful thermal conduction that would otherwise enable runaway propagation.
2Reliability
If thermal insulation elements are added between cells to prevent thermal runaway, then thermal protection improves, but space utilization deteriorates
Solution Approach 1:
The patent employs thin film-like thermal insulation elements that provide effective thermal barrier properties while occupying minimal volume. These thin insulation layers deliver adequate thermal protection without significantly increasing the overall package volume or reducing space utilization.
3Reliability
If compression force is increased to improve cell contact and electrical connection, then electrical connection improves, but mechanical stress on cells increases
Solution Approach 1:
The patent applies compression force locally at specific contact points between cells and current collectors rather than uniformly across all cell surfaces. This localized compression strategy ensures adequate electrical connection at critical interfaces while minimizing overall mechanical stress on the cell structures.
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 enhances space utilization, improves power-to-weight ratios, and effectively mitigates thermal runaway risks by absorbing heat and providing thermal resistance, thereby protecting cells and maintaining safe energy release scenarios.
Implementation Method 1
The compressible aerogel provides heat transfer resistance
Implementation Method 2
The PCM can absorb heat generated during a thermal runaway of a given battery cell
Implementation Method 3
The PCM can absorb heat generated during a thermal runaway of a given battery cell
Data Source
AI summary
A battery cell module (10) having a plurality of flat battery cells (1) arranged side by side in a stack, a layer of a compressible aerogel (17) between al least two of the battery cells (1), at least one phase change material (PCM) layer (18), and a circuit arrangement with battery cell management electronics (14a) in operative connection with said plurality of battery cells. At least two compression plates (11) are arranged on opposite sides of said stack and are operable in a cell compression direction (CD) to hold said stack together therebetween. A separation layer (19) is arranged between the stack and the circuit arrangement. A battery cell arrangement from such modules is also provided.