Battery Pack Thermal Barrier Assembly With Integrated Routing Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electrified vehicles, thermal energy can propagate between battery arrays, leading to potential thermal runaway events, and existing solutions fail to effectively compartmentalize and secure routable components within the traction battery pack.
Innovation Solution
A thermal barrier assembly is positioned between battery arrays, secured to cross-members, with lips that interface with the arrays and channels to route and retain components, using polymer-based materials to block thermal energy and secure the cover, thereby compartmentalizing the pack and preventing thermal energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal barriers are placed between battery arrays to block thermal energy, then thermal runaway prevention is improved, but device complexity increases due to additional components and assembly steps
Solution Approach 1:
The patent combines multiple functions into a single integrated thermal barrier assembly that simultaneously provides thermal isolation, structural support for battery arrays, and routing channels for electrical components. This merging eliminates the need for separate support structures and routing mechanisms, thereby reducing overall assembly complexity while maintaining thermal runaway prevention capabilities
Solution Approach 2:
The thermal barrier assembly serves multiple purposes: it acts as a thermal insulator between battery arrays, provides structural support and positioning for the arrays, and incorporates integrated channels for routing busbars and coolant hoses. This multi-functionality reduces the total number of components needed in the battery pack assembly
2Ease of manufacture
If battery arrays are secured to cross-members directly, then assembly is simplified, but thermal energy can still propagate between arrays
Solution Approach 1:
The thermal barrier assembly acts as an intermediary component positioned between the battery arrays and the cross-members. It provides the necessary thermal isolation while still allowing the arrays to be securely mounted to the cross-member structure, thus preventing thermal propagation without compromising structural support
3Ease of operation
If routable components are routed through the thermal barrier assembly, then component organization is improved, but manufacturing precision requirements increase
Solution Approach 1:
The routing channels for busbars and coolant hoses are pre-formed and integrated into the thermal barrier assembly during its manufacturing process. This preliminary action ensures proper alignment and positioning are built into the structure itself, reducing the precision requirements during final assembly operations
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 thermal barrier assembly effectively blocks thermal energy transfer between battery arrays, inhibits thermal runaway, and securely aligns and supports routable components, enhancing the structural integrity and thermal management of the traction battery pack.
Implementation Method 1
the thermal barrier assembly configured to block thermal energy movement from the first battery array to the second battery array, and from the second battery array to the first battery array
Data Source
AI summary
A battery pack system includes first and second battery arrays of a traction battery pack and a thermal barrier assembly disposed at least partially between the first and second battery arrays. The thermal barrier assembly is configured to block thermal energy movement from the first battery array to the second battery array, and from the second battery array to the first battery array. The thermal barrier assembly includes a primary attachment portion, a first lip that interfaces with the first array, and a second lip that interfaces with the second array. The system further includes a routable component of the traction battery pack. The routable component is received within a channel of the first lip and a channel of the second lip.