Battery Cell Flow Guide PCB for Thermal Runaway Venting
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Solution Overview
Problem
Electrochemical storage units face challenges with high temperature resistance and risk of fire, particularly due to thermal runaway events in electrochemical cells, which can lead to explosions and propagation of overheating to neighboring cells.
Innovation Solution
An electrochemical storage unit design incorporating a flow guide element, such as a circuit board with polymer material and fiber reinforcement, which includes predetermined breaking points and flow channels to divert and drain fluids emerging from overheated cells, thereby isolating defective cells and reducing the risk of fire and explosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional battery manufacturing process is used, then production capacity is limited, but manufacturing cost increases and production time extends
Solution Approach 1:
The battery manufacturing process is divided into multiple independent modules: electrode preparation module, assembly module, electrolyte filling module, and sealing module. Each module can operate independently and be optimized separately, enabling parallel production and significantly increasing overall production capacity while maintaining manageable complexity through modular design.
Solution Approach 2:
The patent employs a nested manufacturing approach where electrode sheets are pre-assembled into electrode assemblies, which are then nested within the battery housing along with other components. This nested structure allows for efficient space utilization and streamlined assembly, reducing manufacturing complexity while enhancing production throughput.
2Loss of time
If battery components are not pre-assembled, then assembly is simpler, but production time and costs increase
Solution Approach 1:
Electrode sheets are pre-assembled into complete electrode assemblies before final battery assembly. This preliminary action includes pre-positioning active materials, current collectors, and separators in their correct configurations. By preparing these components in advance, the final assembly process is dramatically accelerated, reducing production time without significantly complicating the overall manufacturing process.
3Productivity
If precise electrode assembly is performed manually, then assembly precision is adequate, but production efficiency is low
Solution Approach 1:
The patent replaces manual mechanical assembly operations with automated positioning and assembly systems. These systems use computer-controlled mechanisms to precisely align and assemble electrode sheets, ensuring consistent positioning accuracy while dramatically increasing assembly speed and productivity compared to manual operations.
4Reliability
If battery components are loosely fitted, then assembly is easier, but sealing performance and reliability deteriorate
Solution Approach 1:
The patent employs precision-engineered component dimensions and tolerances to achieve optimal fit between battery components. By carefully controlling geometric parameters such as electrode sheet dimensions, housing tolerances, and sealing surface profiles, the system achieves reliable sealing performance while maintaining ease of assembly through standardized, pre-configured components.
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 enhances temperature resistance, mechanical stability, and fire protection by effectively managing thermal events and isolating overheated cells, reducing the risk of fire and explosion while maintaining electrical functionality.
Implementation Method 1
a positive electrode and a negative electrode that are capable of occluding and releasing lithium ions reversibly through the use of a specific electrolyte solution
Implementation Method 2
positive electrode and a negative electrode that are capable of occluding and releasing lithium ions reversibly through the use of a specific electrolyte solution
Data Source
Figure 1
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AI summary
In order to provide an electrochemical storage unit, which has a high temperature resistance and in which the risk of fire and/or a flash fire is minimised, according to the invention, the electrochemical storage unit comprises one or more electrochemical cells and a flow guide element, which is connected to at least one of the one or more electrochemical cells, wherein the flow guide element comprises or is formed by a circuit board element, wherein the circuit board element comprises in particular a polymer material, wherein one or more flow channels and/or one or more flow guide elements are formed and/or arranged on a side of the circuit board element facing the one or more electrochemical cells in order to guide a fluid exiting at least one of the one or more electrochemical cells.