Battery Module Phase-Change Powder for Thermal Runaway Containment

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Solution Overview

Problem

Existing cooling solutions for battery packs do not effectively mitigate the spread of thermal runaway energy from one accumulator to others, potentially leading to multiple accumulators entering thermal runaway, and may increase pressure within the module.

Innovation Solution

A battery module incorporating a phase-change metal powder placed in the path of hot gases released during thermal runaway, which changes phase to limit thermal convection and conduction, thereby preventing the propagation of thermal runaway to adjacent accumulators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cooling solutions are used in battery packs, then thermal management is provided, but thermal runaway energy spreads to adjacent accumulators

Engineering Contradiction:

Improvethermal runaway preventionVSAvoidheat transfer

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A phase-change material layer is introduced as an intermediary substance between accumulators. This layer absorbs thermal runaway energy through phase transition (solid to liquid), preventing direct heat transfer to adjacent accumulators. The material acts as a thermal barrier that actively manages heat rather than passively conducting it.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention utilizes phase transition of a material (from solid to liquid) as the primary mechanism for thermal energy absorption. When thermal runaway occurs, the phase-change material absorbs large amounts of heat energy during its phase transition, effectively limiting temperature rise and preventing propagation to neighboring accumulators.

Inventive Principle:

Principle #36Phase transitions

2Temperature

If cooling solutions are implemented to manage thermal runaway, then temperature control is improved, but pressure increases within the module

Engineering Contradiction:

Improvetemperature controlVSAvoidmodule pressure

Core Design Contradiction:

TemperatureVSStress or pressure

Solution Approach 1:

The phase-change material absorbs thermal energy through solid-to-liquid phase transition, which occurs at relatively low temperatures. This prevents the need for high-pressure cooling systems, as the phase-change process itself provides active thermal management without generating significant pressure increases within the battery module.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The invention converts the harmful thermal energy from thermal runaway into a beneficial phase-transition process. The thermal energy that would otherwise propagate damage is instead utilized to drive the phase change of the protective material, transforming a harmful effect into a useful thermal management mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 phase-change metal powder effectively limits the temperature rise and heat transfer to adjacent accumulators, preventing them from entering thermal runaway and reducing the risk of pressure increase within the module.

Implementation Method 1

at least one phase-change metal powder, placed in at least one area intended for the passage of hot gases released by one of the accumulators during thermal runaway, the powder being suitable for changing phase in the area and thus limiting thermal convection of the released hot gases

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS20250174768A1Battery module with at least one accumulator comprising a phase-change metal powder for limiting the propagation of thermal runaway and the associated pressure rise

Publication Date: 2025.05.29 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

AI summary

Battery module with at least one accumulator including a phase-change metal powder to limit the propagation of thermal runaway and the associated pressure rise. A battery module (M) including at least one phase-change metal powder (10), placed in at least one area intended for the passage of hot gases released by one of the accumulators during thermal runaway, the powder being suitable for changing phase in the area and thus limiting thermal convection of the released hot gases.