Battery Module Thermal Runaway Control via Electrical Decoupling

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Solution Overview

Problem

Thermal runaway events in battery systems can propagate rapidly due to excessive heat generation, potentially affecting entire battery arrays, as chemical reactions in lithium-ion cells and external factors lead to uncontrolled temperature increases.

Innovation Solution

A method involving sensors to detect thermal runaway events, an electronic controller to determine if electrical current is flowing, and subsequent electrical decoupling of affected modules from others, along with connecting them to an electrical load for controlled discharge to mitigate the propagation of heat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If battery cells are placed in close proximity to maximize energy density, then productivity and space utilization are improved, but thermal runaway propagation risk increases

Engineering Contradiction:

Improveenergy densityVSAvoidthermal runaway propagation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The battery system is divided into modular battery modules, each with independent thermal management and electrical isolation capabilities. This segmentation allows heat to be contained within individual modules, preventing propagation to other modules while maintaining high energy density through close modular arrangement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Thermal barriers and isolation materials are introduced between adjacent battery modules to act as intermediaries that block heat transfer. These intermediary elements prevent thermal runaway propagation while allowing the modules to remain in close proximity for high energy density.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If electrical decoupling is implemented to prevent thermal runaway propagation, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvethermal runaway controlVSAvoidelectrical circuit configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrical circuit configuration dynamically switches between connected and decoupled states based on thermal conditions. During normal operation, modules are electrically connected for optimal performance; during thermal runaway events, the system automatically decouples affected modules, providing both reliability and simplicity contextually.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Temperature sensors continuously monitor battery module conditions and provide feedback to the control system. When thermal runaway is detected, the feedback triggers automatic electrical decoupling of the affected module, improving reliability without requiring complex manual intervention circuits.

Inventive Principle:

Principle #23Feedback

3Duration of action of moving object

If rapid thermal response is implemented to control thermal runaway, then the duration of the event is reduced, but the severity of thermal stress on components increases

Engineering Contradiction:

Improvethermal runaway durationVSAvoidthermal stress

Core Design Contradiction:

Duration of action of moving objectVSStress or pressure

Solution Approach 1:

The battery system is segmented into independent modules with individual thermal management systems. This segmentation localizes thermal stress to specific modules, allowing rapid response to control thermal runaway duration without subjecting the entire system to severe thermal stress.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different thermal management strategies are applied to different battery modules based on their specific thermal conditions. Modules experiencing thermal runaway receive rapid active cooling, while modules at risk but not yet in runaway receive preventive cooling, optimizing response time while minimizing overall thermal stress.

Inventive Principle:

Principle #3Local quality

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

This approach effectively controls the propagation of thermal runaway events by reducing the state of charge in adjacent modules, thereby minimizing the duration and severity of the event within the battery system.

Implementation Method 1

electrically connecting the second battery module to an electrical load to discharge the second battery module through the electrical load. Discharging the second battery module thusly is intended to control propagation of the thermal runaway event through the second battery module

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11264815B2Control of thermal runaway event in battery system

Publication Date: 2022.03.01 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method of controlling a thermal runaway event in a battery system having first and second battery modules. The method includes detecting a thermal runaway event in the first battery module, and, in response to the detection of the thermal runaway event, determining whether an electrical current is flowing through the first battery module. The method also includes electrically decoupling the first battery module from the second battery module in response to the detection of the thermal runaway event, if the current is not flowing through the first battery module. Furthermore, the method includes electrically connecting the second battery module to an electrical load to discharge the second module through the load, if the current is determined to be flowing through the first battery module or after decoupling the first module. Discharging the second battery module is intended to control propagation of the thermal runaway event through the second module.