Electrolyte Flushing Battery Design for Thermal Runaway Mitigation

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Solution Overview

Problem

Lithium-ion batteries are prone to thermal runaway due to internal shorts caused by latent manufacturing defects, leading to high temperatures and potential ignition or explosion, which current cooling methods fail to prevent or mitigate.

Innovation Solution

An electrolyte flushable battery apparatus with hermetically sealed inlet and outlet valves that open during thermal runaway, using a non-conductive flushing liquid to expel electrolyte through a pumping system, monitored by a battery management system to detect early signs of thermal runaway.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If cooling methods are used to manage battery temperature, then thermal control is improved, but thermal runaway cannot be prevented

Engineering Contradiction:

Improvebattery temperature controlVSAvoidthermal runaway prevention

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent extracts the harmful electrolyte from the battery system by flushing it out through the electrolyte removal device when thermal runaway is detected, separating the harmful substance from the battery to prevent ignition and explosion

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent performs preliminary action by detecting early signs of thermal runaway through monitoring temperature and voltage, then activating the electrolyte removal system before the thermal runaway completes, preventing the catastrophic event from occurring

Inventive Principle:

Principle #10Preliminary action

2Reliability

If hermetically sealed valves are used to prevent leakage, then sealing reliability is improved, but valve opening response during thermal runaway may be delayed

Engineering Contradiction:

Improvevalve sealingVSAvoidvalve opening response

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

The patent changes the parameter of valve operation from static sealed state to dynamic responsive state by using thermally-responsive materials or actuators that automatically open the hermetically sealed valves when temperature thresholds are exceeded during thermal runaway

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional mechanical valve actuation with alternative mechanisms such as thermal expansion, phase change materials, or electronic actuators that can rapidly open hermetically sealed valves in response to thermal runaway conditions

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Effectively reduces the risk of thermal runaway by flushing out the electrolyte, minimizing the chance of ignition and explosion, applicable in servers, UPS systems, and electric vehicles.

Implementation Method 1

The flushing liquid flows through the battery apparatus in response to a thermal runaway event

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

The method monitors at least one condition of the electrolyte flushable battery apparatus to detect a potential thermal runaway event based on the at least one condition exceeding a threshold value

Methodology Applied

Scientific EffectThermal detection:

Data Source

PatentUS12537263B2Thermally activated retractable EMC protection

Publication Date: 2026.01.27 INTERNATIONAL BUSINESS MACHINE CORPORATION

AI summary

A system and method for flushing the electrolyte out of an electrolyte flushable battery apparatus during a thermal runaway event. At least one condition of the electrolyte flushable battery apparatus is monitored to detect a potential thermal runaway event based on the at least one condition exceeding a threshold value. In response the inlet valve and outlet valves on the battery apparatus are opened. A flushing liquid is flushed or pumped through the battery apparatus where the flushing liquid enters the apparatus through the inlet valve and leaves the apparatus through the outlet valve. The flushing liquid is then stored in a reservoir.