Battery Assembly Filler for Thermal Runaway Blocking
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Solution Overview
Problem
The spread of thermal runaway events in battery cells, leading to fires or explosions, is a significant safety concern in battery assemblies, particularly in electric vehicles, due to the potential for flame transfer through empty spaces between cells.
Innovation Solution
Incorporating a compressible filler member made of materials like foamed urethane or silicone into the insertion spaces between battery cells and busbars, which can deform to accommodate cell expansion and block or vent high-temperature gas, thereby preventing thermal propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If empty spaces are left between battery cells, then ease of assembly and thermal management are improved, but thermal propagation risk increases
Solution Approach 1:
A filler member is introduced as an intermediary substance in the insertion space between battery cells. This filler member has fire retardancy and can block or delay thermal propagation while still allowing for ease of assembly. The filler member acts as a mediator that prevents direct flame transfer through empty spaces while maintaining the beneficial spacing for assembly and thermal management.
2Reliability
If filler material is added to insertion spaces, then thermal stability is improved, but device complexity increases
Solution Approach 1:
The filler member is designed to perform multiple functions simultaneously: it provides fire retardancy to block thermal propagation, maintains electrical insulation between cells, and can be compressed to accommodate cell expansion during charging. By consolidating these multiple functions into a single component, the solution improves thermal stability without proportionally increasing device complexity.
3Object-affected harmful factors
If rigid filler material is used, then fire resistance is improved, but adaptability to cell expansion decreases
Solution Approach 1:
The filler member's physical parameters are specifically selected to achieve the desired balance: it has fire retardancy properties to resist flames, but also possesses compressibility to change its volume in response to cell expansion. This parameter optimization allows the filler member to maintain fire resistance while adapting to dimensional changes of battery cells during operation.
4Object-affected harmful factors
If compression force is applied to filler member, then thermal blocking is improved, but mechanical stress on cells increases
Solution Approach 1:
The filler member is designed with dynamic compressibility, allowing it to be compressed during assembly to provide thermal blocking, but to rebound and maintain a relaxed state during normal operation. This dynamic behavior enables the filler member to provide thermal protection when needed while minimizing mechanical stress on battery cells during regular charging and discharging cycles.
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 delays and blocks thermal propagation, enhancing the thermal stability and safety of battery assemblies by containing high-temperature gas and reducing the risk of fire spread.
Implementation Method 1
the filler member may comprise a compressible material
Implementation Method 2
when at least one of the plurality of battery cells expands, the volume may decrease from the first volume according to the expansion of the at least one battery cell
Implementation Method 3
the filler member may have at least one of electrical insulation or fire retardancy
Data Source
AI summary
The present disclosure relates to a battery assembly comprising a plurality of battery cells, a receiving case configured to accommodate the plurality of battery cells, an insertion space formed between the plurality of battery cells and the receiving case, and a filler member disposed in the insertion space, wherein the filler member comprises a compressible material.