Battery Pack CCS Cooling for Thermal Runaway Venting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Battery packs face risks of thermal runaway due to insufficient protective measures, leading to heat spread and potential combustion or explosion, affecting safety and normal use.
Innovation Solution
A battery pack design incorporating a cells contact system (CCS) assembly with a first channel positioned to spray coolant to explosion-proof valves, integrating a wire harness separator with accommodation grooves for the wire harness and electrical connector, and including a reinforcing structure to stabilize the spray mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery pack design without CCS assembly is used, then device complexity is reduced, but safety against thermal runaway is insufficient
Solution Approach 1:
The CCS assembly is divided into functional modules: cooling channels integrated into the battery housing, explosion-proof valves on individual cells, and a control unit. This segmentation allows the safety system to be added without requiring complete redesign of the battery pack, thus improving safety while limiting complexity increase.
Solution Approach 2:
The CCS assembly acts as an intermediary system between the cells and the external environment. It provides a controlled interface for thermal management and safety monitoring, enabling safety improvements without directly modifying the cell structure or requiring complex integration with external systems.
2Temperature
If cooling channels and spray portions are added to CCS assembly, then cooling effect on thermal runaway cells is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The cooling channels are merged with the battery housing structure, and the spray portions are integrated into the CCS assembly housing. This combining of functions reduces the number of separate components, simplifies manufacturing processes, and lowers assembly complexity while maintaining effective cooling capability.
Solution Approach 2:
The CCS assembly housing serves multiple functions: it contains the cooling channels, provides structural support, and integrates the spray portions. This multi-functionality reduces the overall component count and simplifies manufacturing compared to having separate dedicated components for each function.
3Reliability
If wire harness separator with accommodation grooves is used, then wire harness organization and safety are improved, but manufacturing complexity increases
Solution Approach 1:
The accommodation grooves for wire harnesses are pre-formed during the injection molding process of the wire harness separator. This preliminary action eliminates the need for separate wire routing channels or additional assembly steps, improving wire harness organization while keeping manufacturing relatively simple.
4Speed
If CCS assembly with spray portions positioned at explosion-proof valves is implemented, then response speed to thermal runaway is improved, but manufacturing precision requirements increase
Solution Approach 1:
The spray portions are pre-positioned and fixed to the CCS assembly housing during manufacturing, with their positions predetermined to align with explosion-proof valve locations. This preliminary positioning reduces the need for complex real-time adjustment mechanisms, maintaining fast response speed while managing manufacturing precision requirements.
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 effectively cools down cells undergoing thermal runaway, reduces the risk of combustion and explosion, improves safety, and enhances energy density by saving space and weight, while ensuring rapid response and reliable operation.
Implementation Method 1
the first channel sprays the liquid correspondingly to the explosion-proof valves... effectively cools down cells undergoing thermal runaway
Data Source
AI summary
A battery pack, including a cell assembly and a CCS assembly. The cell assembly includes a plurality of cells, each of which is electrically connected through an electrical connector. The CCS assembly is located at a side of the cell assembly and is electrically connected to the electrical connector through a wire harness. The CCS assembly includes a first channel. A position where the first channel is positioned corresponds positions where explosion-proof valves of the plurality of cells are positioned, such that liquid is sprayed to the explosion-proof valves. The CCS assembly includes a wire harness separator, the wire harness separator includes a first accommodation groove, in which the wire harness and the electrical connector are received. When the cell undergoes thermal runaway and causes the explosion-proof valve to spray high-temperature heat flow, coolant in the first channel is sprayed to the position of the explosion-proof valve.