Multilayer Battery Pack Enclosure for Thermal Vent Containment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery pack enclosures in electrified vehicles face challenges in managing vent byproducts from thermal events, which can lead to uncontrolled discharge and potential damage to adjacent battery cells.
Innovation Solution
A multilayer structure enclosure assembly with an apertured core impregnated with resin, comprising an outer and inner shell, provides structural integrity and thermal resistance, while bonding the layers together to contain and manage vent byproducts effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-layer enclosure is used, then the manufacturing process is simple, but the enclosure cannot effectively contain and manage vent byproducts from thermal events
Solution Approach 1:
The enclosure is divided into multiple functional layers: an outer shell for structural protection, an intermediate apertured core layer for filtering and containing vent byproducts, and an inner shell for additional containment. This segmentation allows each layer to perform its specific function, improving overall reliability in managing thermal events while maintaining manufacturing feasibility through modular assembly
Solution Approach 2:
The enclosure combines different material types and structures into a composite assembly. The apertured core uses a three-dimensional mesh structure with controlled porosity, while the outer and inner shells provide structural integrity. This composite approach enables the enclosure to simultaneously achieve structural strength, thermal management, and vent byproduct containment that a single material could not provide
2Object-generated harmful factors
If the apertured core has high porosity to allow vent byproduct passage, then vent byproducts can escape, but structural integrity of the enclosure is compromised
Solution Approach 1:
The apertured core exhibits local quality variations with different porosity regions optimized for specific functions. Certain areas have higher porosity to facilitate vent byproduct passage and thermal management, while other regions maintain lower porosity to preserve structural integrity. The aperture size, shape, and distribution are locally optimized to balance containment effectiveness with structural strength
Solution Approach 2:
The combination of the apertured core with outer and inner shells creates a composite structure where the shell layers provide the primary structural strength while the apertured core provides the vent byproduct management function. This composite approach allows the apertured core to have sufficient porosity for effective venting without compromising overall enclosure integrity, as the shells bear the structural loads
3Reliability
If multiple layers are added to improve vent byproduct containment, then containment effectiveness increases, but manufacturing complexity increases
Solution Approach 1:
The multi-layer enclosure is designed as segmented modules that can be manufactured separately and assembled together. The outer shell, apertured core, and inner shell can be produced using different optimized processes and then bonded together, allowing each component to be manufactured with appropriate complexity for its specific function while simplifying overall production through modular assembly
Solution Approach 2:
The apertured core acts as an intermediary layer between the outer and inner shells, providing the critical vent byproduct management function. This intermediate layer design allows the outer and inner shells to focus on structural containment while the apertured core handles the complex venting and thermal management functions, distributing the manufacturing complexity across specialized components rather than requiring one highly complex integrated structure
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 multilayer structure effectively contains and manages vent byproducts, preventing further cell activation and enhancing the enclosure's durability and thermal management capabilities.
Implementation Method 1
the multilayer structure at least partially impregnated with a resin
Implementation Method 2
the resin at least partially fills the plurality of apertures of the apertured core
Implementation Method 3
provides structural integrity and thermal resistance
Data Source
AI summary
A traction battery pack assembly includes an enclosure assembly configured to house a plurality of battery cells within an interior area. The enclosure assembly is at least partially provided by a multilayer structure having an apertured core with one or more layers sandwiched between an outer shell and an inner shell. The apertured core has a plurality of apertures. The multilayer structure is at least partially impregnated with a resin.