Battery Thermal Runaway Gas Pathway Separation

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Solution Overview

Problem

Lithium-ion battery systems face challenges during thermal runaway events, where flammable gases can ignite and cause explosions due to mixing with cooling air, leading to potential enclosures rupture and destructive events.

Innovation Solution

A system with physically separated pathways for cooling air and thermal runaway gases, using a manifold and separator to direct thermal runaway gases away from cooling air, minimizing their mixing and incorporating a flame arrestor to prevent ignition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If thermal runaway gases are vented from battery modules, then pressure relief is achieved, but the gases may mix with surrounding air and spontaneously combust

Engineering Contradiction:

Improveinternal pressureVSAvoidspontaneous combustion

Core Design Contradiction:

Stress or pressureVSObject-affected harmful factors

Solution Approach 1:

The venting system is segmented into separate pathways: one for thermal runaway gases and another for cooling air. The separator physically divides these pathways, ensuring that vented gases do not mix with cooling air, thereby preventing spontaneous combustion while maintaining pressure relief functionality

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A separator acts as an intermediary component between the thermal runaway gas pathway and the cooling air pathway. This separator prevents direct contact and mixing between the two gas streams, eliminating the fire hazard while allowing both pathways to function independently

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If a blower is used to flow air over battery modules for cooling, then heat removal is improved, but thermal runaway gases are at greater risk of mixing with surrounding air

Engineering Contradiction:

Improveheat removalVSAvoidgas mixing

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The airflow system is segmented into distinct zones: a cooling air pathway that allows the blower to effectively cool battery modules, and a separate thermal runaway gas pathway that channels vented gases away from the cooling air stream, preventing mixing despite the presence of the blower

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator creates a spatial dimension that physically divides the airflow paths. By introducing this vertical or lateral separation, the system allows the blower to maintain strong cooling airflow while thermal runaway gases are directed through a separate dimensional pathway, eliminating the mixing risk

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Temperature

If cooling air flows over battery modules, then thermal management is achieved, but mixing with thermal runaway gases can occur

Engineering Contradiction:

Improvecooling efficiencyVSAvoidflammable mixture

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The system segments the gas flow paths by introducing a separator that divides the enclosure into distinct regions. Cooling air flows freely over battery modules in one region, while thermal runaway gases are channeled through a separate pathway in another region, maintaining cooling efficiency while preventing flammable mixture formation

Inventive Principle:

Principle #1Segmentation

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 separation of thermal runaway gases from cooling air reduces the risk of spontaneous ignition and explosion, ensuring safer operation of lithium-ion battery systems by preventing flammable mixtures above the lower flammability limit.

Implementation Method 1

a separator that physically separates the cooling air pathway and the thermal runaway gas pathway such that cooling air flowing along the cooling air pathway does not substantially mix with thermal runaway gas venting from the at least one energy cell

Methodology Applied

Scientific EffectPhysical separation:

Implementation Method 2

incorporating a flame arrestor to prevent ignition

Methodology Applied

Scientific EffectFlame arrestion:

Data Source

PatentUS11217857B2Method and apparatus for managing thermal runaway gases in a battery system

Publication Date: 2022.01.04 CORVUS ENERGY INC

AI summary

A system comprising one or more battery modules mounted in a rack assembly has a structure which defines a cooling air pathway for flowing cooling air across the side and/or bottom of each battery module thereby cooling the battery module, or alternatively, across the energy calls in the battery module. Further, the system has a structure which defines a thermal runaway gas pathway for flowing thermal runaway gases from a battery module out of the system. The system structure is configured to ensure that the cooling air pathway and thermal runaway gas pathway are physically separated, thereby minimizing the risk of the thermal runaway gas substantially mixing with cooling air thereby potentially resulting in a spontaneous ignition and an explosion.