Battery Module Cover Structure With Segmented Thermal Runaway Venting
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Solution Overview
Problem
Thermal runaway in battery packs poses a significant risk of fire or explosion due to uncontrolled heat generation and gas release, necessitating improved designs to manage hot gases and particles effectively.
Innovation Solution
A cover structure with abrasion-resistant cover plates featuring breakable openings and alignment elements, integrated with holding rails, facilitates controlled gas exhaust and precise alignment, enhancing safety and structural integrity during thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single solid cover plate is used to protect battery cells, then structural protection is improved, but pressure buildup from thermal runaway cannot be released
Solution Approach 1:
The cover structure is segmented into multiple cover plates (first cover plate, second cover plate, etc.) that can be positioned at different locations above battery cells. Each cover plate can independently respond to thermal events, allowing localized pressure release while maintaining overall structural protection.
Solution Approach 2:
The cover plates incorporate localized breakable openings rather than being completely solid or completely open. This allows the cover to maintain structural integrity in most areas while providing specific localized pathways for gas venting when thermal runaway occurs.
2Object-affected harmful factors
If the entire cover structure is made breakable to allow gas exhaust, then pressure release is improved, but structural stability deteriorates
Solution Approach 1:
The cover structure divides the breakable functionality into separate cover plates positioned at specific locations rather than making the entire cover breakable. This segmentation allows gas exhaust at specific points while maintaining structural stability in other areas.
Solution Approach 2:
Only specific portions of the cover plates (the breakable openings) are designed to break, while the rest of the cover plate structure remains intact and provides structural support. This localized breakability resolves the contradiction between gas exhaust and structural stability.
3Strength
If cover plates are tightly secured to prevent lifting, then structural integrity is improved, but individual response to thermal events is hindered
Solution Approach 1:
The cover structure uses multiple independently positionable cover plates rather than a single monolithic cover. This allows each cover plate to respond independently to thermal events at its location while the overall segmented structure maintains structural integrity through the rail mounting system.
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 cover structure effectively manages pressure buildup and gas release, minimizing the risk of fire or explosion by isolating thermal stress to individual cover plates, maintaining structural stability and protecting battery control components.
Implementation Method 1
breakable opening configured to facilitate gas exhaust in the event of a thermal runaway
Implementation Method 2
alignment elements being configured to engage with the corresponding alignment elements of the first and second holding rails to position each cover plate
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~2D
AI summary
A cover structure (100) for a battery module and a battery module configured to hold a plurality of battery cells, the cover structure comprising: a first holding rail (102) and a second holding rail (104), each holding rail having corresponding alignment elements (112a-b); and a plurality of abrasion-resistant cover plates (106) positioned between the first holding rail and the second holding rail, wherein each cover plate includes a breakable opening (108) configured to facilitate gas exhaust in the event of a thermal runaway; and each cover plate comprises alignment elements (110a-b) at opposing ends, the alignment elements being configured to engage with the corresponding alignment elements (112a-b) of the first and second holding rails to position each cover plate between the first and second holding rails.