Battery Module Cover Vent Layout to Limit Thermal Runaway Spread

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Solution Overview

Problem

Battery modules face challenges in controlling thermal runaway events, where excessive heat generated by one cell can spread to adjacent cells, leading to uncontrolled temperature increases and potential damage to the entire module.

Innovation Solution

A battery module top cover with vent features, including exhaust openings and a resilient sealing element, is designed to expel high temperature gases away from adjacent cells, minimizing gas transfer and controlling thermal runaway propagation. The cover is configured with a reverse scoop shape to direct gases away from neighboring cells and includes liner segments and a heat sink to absorb thermal energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery cells are positioned in close proximity to maximize space utilization, then productivity and space efficiency are improved, but heat transfer between cells increases leading to thermal runaway propagation

Engineering Contradiction:

Improvespace utilizationVSAvoidheat transfer between cells

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an insulating member as an intermediary element positioned between adjacent battery cells. This mediator reduces thermal coupling between cells while maintaining their close proximity arrangement, thereby preventing heat transfer during thermal runaway events without sacrificing space utilization efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a sealed enclosure is used to protect battery cells from external environment, then reliability is improved, but pressure buildup from thermal runaway gases increases safety risks

Engineering Contradiction:

Improveprotection from external environmentVSAvoidpressure buildup from thermal runaway gases

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The patent extracts the harmful thermal runaway gases from the sealed enclosure by providing dedicated exhaust openings. These openings allow gases to be vented externally, relieving internal pressure buildup while maintaining the protective enclosure structure for normal operation

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The exhaust openings are designed to activate during phase transition conditions when thermal runaway occurs. The structural integrity of the enclosure is maintained during normal operation, but the openings facilitate gas release when temperature and pressure conditions indicate thermal runaway

Inventive Principle:

Principle #36Phase transitions

3Reliability

If exhaust openings are provided to vent thermal runaway gases, then safety is improved, but high temperature gases may still reach adjacent cells causing thermal runaway propagation

Engineering Contradiction:

Improvesafety from thermal runawayVSAvoidgas transfer to adjacent cells

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by providing cell-specific exhaust openings positioned adjacent to each battery cell. Each opening is locally optimized to vent gases from its corresponding cell in a controlled direction, ensuring that hot gases are expelled away from neighboring cells rather than allowing uncontrolled spread

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The exhaust openings are configured to vent gases in a directional manner, utilizing spatial dimensionality to channel hot gases away from adjacent cells. The openings are positioned and angled to exploit the three-dimensional space around each cell, directing exhaust flow in specific directions that avoid neighboring cells

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Reliability

If insulating members are placed between battery cells to reduce heat transfer, then thermal runaway mitigation is improved, but device complexity increases

Engineering Contradiction:

Improvethermal runaway mitigationVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating member is designed to perform multiple functions simultaneously: it provides thermal insulation between cells, serves as a structural spacer to maintain cell positioning, and acts as a mounting substrate for the exhaust opening system. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 mitigates the spread of thermal runaway events by directing high temperature gases to the external environment, reducing the risk of heat transfer between cells and maintaining module stability during extreme conditions.

Implementation Method 1

The exhaust openings may be positioned relative to the first and second battery cells such that the exhaust openings expel rising high temperature gases at an uppermost or highest level of the battery module enclosure

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Implementation Method 2

The resilient sealing element may include lateral sections arranged distally from the channel and configured to maintain contact with the battery module cover under pressure from the high temperature gases

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Implementation Method 3

The reverse scoop shape may be configured to direct the high temperature gases at an angle that is greater than 90 and less than 180 degrees relative to the cover plane

Methodology Applied

Scientific EffectFluid flow direction:

Implementation Method 4

The battery module may additionally include a heat sink arranged opposite the battery module cover, mounted to the battery module enclosure, and configured to absorb thermal energy from the first and second battery cells

Methodology Applied

Scientific EffectHeat absorption: Heat Sink

Implementation Method 5

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 6

The vent feature may include liner segments configured to cover the exhaust openings and be blown off the exhaust openings by the high temperature gases to thereby expel the high temperature gases from the first battery cell to the external environment

Methodology Applied

Scientific EffectPressure force: Pressure Increase

Data Source

PatentUS12046773B2Battery module cover with thermal runaway mitigation

Publication Date: 2024.07.23 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A battery module includes a first battery cell and a neighboring second battery cell, and an insulating member positioned therebetween. The battery module also includes a battery module enclosure surrounded by an external environment and configured to house each of the first battery cell, the second battery cell, and the insulating member. The battery module additionally includes a battery module cover mounted to the battery module enclosure. The battery module cover includes a vent feature configured to expel high temperature gases from the first battery cell and divert the high temperature gases away from the second battery cell directly to the external environment. The cover is thereby configured to minimize transfer of the high temperature gases from the first battery cell to the second battery cell and control propagation of a thermal runaway event in the battery module.