Battery Module Rail Isolation for Thermal Runaway Containment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increase in the number of cells in a battery pack increases the risk of overheating and thermal runaway due to heat generation, posing safety hazards and efficiency challenges.
Innovation Solution
The battery pack design includes a casing with rails and couplers that secure battery modules, providing thermal insulation and venting mechanisms to prevent heat transfer and pressure buildup, along with bus bars that de-energize in case of thermal runaway to ensure safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of cells in a battery pack is increased to provide sufficient electricity, then the power output is improved, but the risk of overheating and thermal runaway increases
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing a subset of cells. This segmentation allows for better thermal management of each module independently and isolates potential thermal runaway events to specific modules rather than affecting the entire battery pack at once.
Solution Approach 2:
Thermal insulation materials are introduced as intermediaries between adjacent battery modules to prevent heat transfer. These materials act as thermal barriers that block the propagation of heat from one module to another, thereby mitigating the risk of thermal runaway spreading across the battery pack.
2Reliability
If thermal insulation is added between battery modules to prevent heat transfer, then thermal runaway mitigation is improved, but the device complexity increases
Solution Approach 1:
The casing structure serves multiple functions: it provides mechanical support for the battery modules, acts as a thermal barrier through integrated insulation layers, and facilitates heat dissipation through designed venting pathways. This multi-functionality reduces the need for separate dedicated components for each function.
Solution Approach 2:
The thermal insulation layers are integrated directly into the casing structure rather than being separate add-on components. The casing combines structural support and thermal insulation functions into a single unified structure, simplifying the overall device architecture.
3Object-affected harmful factors
If venting mechanisms are implemented to prevent pressure buildup, then safety is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The venting mechanisms are designed to activate automatically based on pressure or temperature conditions without requiring external control systems. The structural design itself enables the venting function through predetermined pathways and pressure-sensitive features that open or close based on operational conditions.
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 design enhances thermal runaway mitigation by preventing heat transfer between modules, reducing vibration noise, and ensuring passenger safety by increasing stiffness and isolating failed cells, thereby improving overall battery performance and safety.
Implementation Method 1
an insulating material disposed between individual cells of the plurality of cells may mitigate effects of thermal runaway of a single cell by isolating the cell from other cells proximate thereto
Implementation Method 2
the battery module may include a cover configured to reduce heat transfer between the battery module and another battery module inserted above the battery module
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A battery pack for a vehicle electrical system includes a casing for receiving one or more battery modules. The battery modules are insertable into a casing of the battery pack by sliding couplers along pairs of rails and are securable to the ends of the rails. After insertion, the rails thermally insulate one battery module from other battery modules in the battery pack. Additionally, the battery modules may be configured to prevent electrical arcing, such as to prevent a thermal runaway event. The battery modules may provide power to a drive module of a vehicle via high-voltage bus bars. The high-voltage bus bars may be configured to de-energize in the event of a thermal runaway or other failure of a battery module of the associated battery pack, thereby improving the safety of the battery pack operation.