Modular Battery Housing With Chimney Cooling for Thermal Runaway
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Solution Overview
Problem
Existing battery systems in rail vehicles face challenges in preventing thermal runaway (TRA) and subsequent fires, which can be costly and unsafe, especially due to the high energy density of lithium ion cells.
Innovation Solution
A battery system frame and method that accommodates multiple lithium ion battery modules in a separate housing made of fire-resistant, thermally insulating material, with a pressure relief arrangement, thermal insulation, and a chimney effect for controlled heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a TRA-resistant container for the entire battery system is produced, then safety against thermal runaway is improved, but cost increases and the container requires a heavy outer housing
Solution Approach 1:
The patent divides the battery system into modular battery modules, each housed in its own separate housing. Instead of protecting the entire battery system with one heavy TRA-resistant container, each module is independently protected. This segmentation allows the safety function to be distributed across multiple lighter units rather than concentrated in one heavy structure.
Solution Approach 2:
The patent applies fire-resistant and thermally insulating materials locally to the housing of each individual battery module rather than requiring a heavy outer housing for the entire system. The housing of each module is made from materials that provide local fire protection and thermal insulation, achieving system-wide safety through localized material properties.
2Reliability
If safer lithium ion cells with reduced TRA energy and protective mechanisms are used, then safety against thermal runaway is improved, but cost increases
Solution Approach 1:
The patent introduces an intermediary protective structure (the housing with fire-resistant and thermally insulating materials) between the battery cells and the external environment. Instead of modifying the cells themselves to be safer, the housing acts as a mediator that contains and manages thermal runaway events, protecting surrounding components and enabling the use of standard, more cost-effective battery cells.
3Reliability
If fire-retardant barriers such as phase-change materials are provided between individual cells, then safety against fire propagation is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the fire protection function from the internal cell structure and places it at the module level. Instead of inserting fire-retardant barriers between individual cells within a module, the housing of each module provides the fire protection externally. This extraction simplifies the internal cell structure while maintaining fire propagation resistance at the module level.
4Temperature
If active cooling water supply is provided into the system, then cooling effectiveness is improved, but reliability during vehicle shutdown deteriorates due to water fill level concerns
Solution Approach 1:
The patent accepts that active cooling systems have reliability issues during shutdown and converts this potential harm into a benefit by designing passive thermal management features. The housing materials and air gap structures are designed to naturally manage heat dissipation without requiring active cooling, turning the limitation of passive thermal management into a reliable solution that works independently of vehicle operation status.
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 restricts fires to individual battery modules, reduces damage and risk to maintenance workers, and allows for the use of less expensive, high-energy-density lithium ion cells while maintaining safety and system functionality.
Implementation Method 1
the thermal insulation effect in particular being enhanced by a thermal insulation (WD) mounted on the inner wall of the housing
Implementation Method 2
these air gaps are connected and configured such that they form a structure which dissipates heat given off by the respective battery module (B1 . . . B4) by virtue of a chimney effect in a controlled way
Data Source
AI summary
Some embodiments of the teachings herein include a battery system. One example includes: a first battery module; and a second battery module adjacent to the first battery module. The modules are each formed of multiple battery cells arranged in separate housings made of a fire-resistant, thermally insulating material. A pressure relief arrangement acts on the housings. The housings each include a fire-resistant interface. The housings are each connected to an exhaust gas port so gases emitted are discharged using a fire-resistant exhaust air device. The housing, the interface, and/or the pressure relief arrangement at least temporarily hermetically seal the battery modules. An open support structure defines a multiplicity of air gaps formed between the first housing and adjoining surfaces thermally connected to the second housing, and the air gaps form a structure dissipating heat given off by the respective battery module with a chimney effect.