Battery Frame with Thermal Barrier Plugs for Cell Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing portable electrical energy storage devices face challenges in managing the risk of lithium-ion battery failure, particularly in multi-cell deployments, where a failed battery can cause adjacent cells to fail due to thermal energy propagation and combustion, posing hazards to users.
Innovation Solution
A frame for retaining individual electrical energy storage cells in an array within a portable device, made from a lightweight, strong material with thermal barrier properties, featuring receptacles with varying wall thicknesses and passageways to prevent thermal energy migration and include a plug with enhanced thermal resistance to contain hot gases and flames, reducing the risk of cell failure and fire propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lithium-ion batteries are deployed in multi-cell configurations to increase energy capacity, then the energy storage capability is improved, but the risk of thermal propagation and fire hazard increases
Solution Approach 1:
The battery pack is divided into multiple independent receptacles, each housing a single battery cell. The receptacles are separated by frame walls that act as thermal barriers, physically segmenting the battery system to prevent thermal runaway propagation between cells while maintaining high energy capacity through multi-cell configuration.
Solution Approach 2:
The frame structure serves as an intermediary thermal barrier between adjacent battery cells. The frame walls, positioned between receptacles, provide thermal isolation that prevents direct heat transfer between cells, thereby reducing thermal propagation risk while allowing close packing for high energy density.
2Quantity of substance
If battery cells are placed in close proximity to maximize space utilization, then the energy density is improved, but the thermal isolation between cells deteriorates
Solution Approach 1:
The frame structure provides localized thermal barrier properties at critical interfaces between battery cells. By concentrating thermal isolation functionality in the frame walls and receptacle structures, the design enables close cell spacing for high energy density while maintaining adequate thermal isolation where it is most needed.
Solution Approach 2:
The frame is constructed from materials with low thermal conductivity, creating a composite structure that combines structural support with thermal isolation functions. This allows the frame to provide both mechanical strength for cell retention and thermal barrier properties for fire hazard mitigation.
3Reliability
If the frame structure is made from materials with high thermal resistance to prevent fire propagation, then the safety is improved, but the heat dissipation capability during normal operation deteriorates
Solution Approach 1:
The thermal management system is segmented into cell-level and pack-level functions. Individual cell housings provide thermal isolation for fire safety, while the overall pack structure incorporates ventilation pathways and heat sink structures that enable collective heat dissipation, separating the thermal isolation and heat dissipation functions.
Solution Approach 2:
The frame structure acts as an intermediary that provides thermal barrier properties for fire safety while incorporating features such as ventilation channels and heat transfer pathways that enable heat dissipation. The frame mediates between the conflicting requirements of thermal isolation and heat dissipation by providing different thermal pathways for different operational modes.
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 frame effectively mitigates the risk of thermal energy transfer between cells, preventing unnecessary failures and reducing the likelihood of external damage from hot gases or flames, thereby enhancing safety and maintaining the integrity of undamaged cells.
Implementation Method 1
a frame for retaining a plurality of individual electrical energy storage cells in an array within a portable electrical energy storage device... made from a lightweight, strong material with thermal barrier properties... to prevent thermal energy migration
Implementation Method 2
include a plug with enhanced thermal resistance to contain hot gases and flames
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A portable electrical energy storage device is provided with a frame (100) that includes a plurality of receptacles (102) for receiving a portion of a portable electrical energy storage cell (200). A cap (910) is provided over the plurality of receptacles (102) and the portion of the portable electrical energy storage cells received in the frame (100). In some embodiments, a passageway (112) extends between adjacent receptacles (102). Disposed within the passageway (112) is a plug which exhibits more resistance to thermal energy migration than other portions of the frame that define the adjacent receptacles.