Battery Cell Potting Layout for Thermal Runaway Isolation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery cell arrangements face challenges in ensuring safety during thermal runaway, as thermal coupling between cells can lead to rapid heat propagation and increased risk of battery fires, while venting channels impair heat dissipation and increase weight.

Innovation Solution

A battery cell arrangement with a potting compound layer that thermally shields battery cells by embedding thermal hotspot areas, such as cell poles and degassing openings, to decouple heat transfer and prevent heat spread, using a thermally insulating potting compound that may ceramize at high temperatures for enhanced fire protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If battery cells are completely embedded in potting compound, then thermal coupling between cells increases, but heat from damaged cells spreads quickly to other cells

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidsafety in case of thermal runaway

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent applies local quality by differentiating the embedding approach: thermal hotspot areas (cell poles and degassing openings) are embedded in thermally insulating potting compound to prevent heat spread, while other parts of the cells remain exposed or are embedded in thermally conductive compound for heat dissipation. This localized differentiation resolves the contradiction between heat dissipation and thermal runaway prevention.

Inventive Principle:

Principle #3Local quality

2Reliability

If venting channels are provided in potting compound, then gases can be discharged from damaged cells, but heat dissipation is impaired and installation space increases

Engineering Contradiction:

Improvegas discharge capabilityVSAvoidheat dissipation efficiency

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent extracts the gas discharge function from the potting compound by providing dedicated gas discharge paths that are separate from the thermal management structure. This allows the potting compound to maintain its thermally conductive properties for heat dissipation while gases are channeled away through separate pathways, resolving the contradiction between gas discharge capability and heat dissipation efficiency.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If battery cells are completely embedded in potting compound, then cells are protected and supported, but overall weight of the battery increases

Engineering Contradiction:

Improvecell protection and supportVSAvoidbattery weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent applies partial action by embedding only the critical thermal hotspot areas (cell poles and degassing openings) in potting compound rather than completely embedding the entire cell. This provides sufficient thermal protection and structural support at the most critical locations while minimizing the amount of potting compound used, thereby reducing overall battery weight while maintaining necessary protection.

Inventive Principle:

Principle #16Partial or excessive action

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

This solution effectively delays or prevents thermal runaway and battery fires by suppressing heat propagation between cells, optimizing weight reduction and maintaining heat dissipation efficiency during normal operation.

Implementation Method 1

the at least one thermal hotspot area is embedded in the potting compound layer, which is formed by a potting compound for thermally shielding the battery cells from one another in case of a thermal runaway

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

using a thermally insulating potting compound that may ceramize at high temperatures for enhanced fire protection

Methodology Applied

Scientific EffectCeramization:

Implementation Method 3

a releasable degassing opening for discharging gases from the relevant battery cell in case of a thermal runaway of the battery cell

Methodology Applied

Scientific EffectGas discharge:

Data Source

PatentUS20230387543A1Battery cell arrangement having a potting compound layer, and method for producing a battery cell arrangement for a motor vehicle

Publication Date: 2023.11.30 AUDI AG

AI summary

A battery cell arrangement for a motor vehicle, having multiple battery cells, which each include two cell poles, a first side, a second side, a height in the direction from the second side to the first side, and a releasable degassing opening for discharging gases from the relevant battery cell in case of a thermal runaway. In case of a thermal runaway, a respective battery cell includes at least one thermal hotspot area, which is provided by at least one of the cell poles and/or the degassing opening, and the battery cell arrangement includes at least one potting compound layer, in which a section of a respective battery cell is embedded in the direction of the height.