Battery Module Diffuser Plate for Single-Cell Thermal Runaway

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Solution Overview

Problem

Lithium ion battery systems face the risk of large battery fires due to cascading failures from a single cell thermal runaway, which can jeopardize personnel and equipment.

Innovation Solution

The battery system incorporates a diffuser plate in each module to direct hot gases and molten material away from neighboring cells during a single cell failure, while also managing residual thermal energy to prevent cascading failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If lithium ion cells are used for higher energy storage capability, then energy storage capacity is improved, but the risk of large battery fires increases due to thermal runaway propagation

Engineering Contradiction:

Improveenergy storage capacityVSAvoidbattery fire risk

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The battery system is divided into multiple modules, each containing a specific number of cells (e.g., 96 cells per module). This segmentation isolates thermal runaway events to individual modules, preventing propagation to the entire battery system. The diffuser plate further segments the module by creating localized containment zones for vented materials.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The diffuser plate acts as an intermediary component between adjacent battery cells. It intercepts hot gases and molten material ejected during thermal runaway, redirecting them away from neighboring cells. This mediator prevents direct contact between failure products and healthy cells, blocking the propagation path.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If cells are arranged in parallel arrays for compact design, then space utilization is improved, but failure propagation risk increases due to closer proximity of cells

Engineering Contradiction:

Improvespace utilizationVSAvoidfailure propagation risk

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The diffuser plate provides localized protection specifically at the vent location of each cell, where thermal runaway ejection occurs. Rather than requiring uniform spacing between all cells, the solution applies targeted intervention at the critical failure point, allowing compact overall arrangement while maintaining local safety zones.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The diffuser plate extends the protection concept from one-dimensional cell spacing to three-dimensional spatial management. By positioning the diffuser plate above the cell vent and creating upward redirection paths, the solution utilizes the vertical dimension to separate failure products from adjacent cells, enabling closer horizontal packing.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If diffuser plates are added to direct hot gases away from neighboring cells, then safety is improved, but device complexity increases due to additional components

Engineering Contradiction:

ImprovesafetyVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The diffuser plate serves multiple functions simultaneously: it acts as a physical barrier to block hot gases, a redirection mechanism to channel vented materials away from cells, a structural support element for the module assembly, and a heat dissipation component. This multi-functionality reduces the need for separate safety components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The diffuser plate is integrated with the existing module structure rather than being a completely separate component. It combines safety functions with the mechanical assembly framework, merging the protective function into the structural design to minimize additional part count.

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively mitigates the risk of battery system failure and associated safety hazards by containing and redirecting the energy from a single cell failure, thereby preventing damage to personnel and property.

Implementation Method 1

the diffuser plate comprising channels on said first side

Methodology Applied

Scientific EffectFluid flow through channels:

Implementation Method 2

Residual thermal energy is wicked away, absorbed or contained to keep heat away from the neighboring cells

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS12203998B2Single cell fault tolerant battery system architecture

Publication Date: 2025.01.21 GENERAL ATOMICS CO

AI summary

A battery system may include multiple battery cells grouped into modules. Each battery module may have a diffuser plate to direct the hot gases and molten material that are ejected during cell failure. The gas and material may be directed away from the nearest neighboring cells in the event of a single cell thermal runaway. Residual thermal energy is wicked away, absorbed or contained to keep heat away from the neighboring cells. These and other features may manage the blast energy and residual thermal energy of a single cell failure event. This may prevent a cascading failure of the larger battery system, thereby mitigating the risk of injury to personnel and property.