Battery Pack Cell Casings for Thermal Runaway Containment
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Solution Overview
Problem
High-energy-density battery packs, particularly those using lithium-ion batteries, are prone to thermal runaway events that can cause extensive damage due to the spread of heat and molten slag from one cell to others, posing a significant risk in aerospace and other applications where containment is critical.
Innovation Solution
The design incorporates a circuit board and casing structures that physically separate and orient cells to direct heat and molten slag away from other cells, using materials with high heat capacity and insulation to absorb and redirect thermal energy, thereby containing thermal events within individual cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cells are positioned close together to reduce device size, then device volume is reduced, but thermal runaway can spread more easily between cells
Solution Approach 1:
The battery pack is divided into separate cell compartments with physical barriers between them. Each cell is isolated within its own designated space, preventing thermal runaway from propagating to adjacent cells while maintaining a compact overall structure.
Solution Approach 2:
Thermal barriers and insulating materials are positioned between cells to act as intermediaries that block heat transfer. These intermediary structures prevent direct thermal contact between cells, allowing close positioning without increasing thermal runaway risk.
2Power
If high-energy-density cells are used to increase power output, then power capacity is improved, but the risk and severity of thermal runaway events increases
Solution Approach 1:
Thermal barriers and protective structures are pre-installed between cells before assembly. These cushioning elements are designed to absorb and redirect thermal energy, providing protection against thermal runaway events before they occur.
Solution Approach 2:
The design channels heat and molten slag from thermal runaway events away from other cells using strategically positioned barriers. The harmful thermal energy is redirected into safe pathways, converting a potentially catastrophic failure mode into a contained event.
3Volume of moving object
If cells are oriented to maximize space utilization, then packing efficiency is improved, but heat dissipation and thermal containment become more difficult
Solution Approach 1:
Cells are oriented in asymmetric configurations with intentional spacing and non-uniform positioning. This asymmetric layout optimizes thermal pathways and heat dissipation while maintaining high space utilization, breaking the symmetry that would otherwise create thermal management challenges.
Solution Approach 2:
The design utilizes three-dimensional spatial arrangement to manage heat flow in multiple directions. By positioning thermal barriers and orienting cells in different spatial dimensions, heat dissipation is enhanced without sacrificing packing efficiency.
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
This design effectively reduces the likelihood and impact of thermal events spreading to other cells, meeting FAA safety requirements and minimizing damage during thermal runaway incidents.
Implementation Method 1
using materials with high heat capacity and insulation to absorb and redirect thermal energy
Implementation Method 2
using materials with high heat capacity and insulation to absorb and redirect thermal energy
Data Source
AI summary
In some examples, a high-energy-density battery pack device includes a circuit board and at least two casing structures mounted on the circuit board. In some examples, the high-energy-density battery pack device also includes at least two cells electrically connected in series or in parallel through the circuit board. In some examples, each cell of the at least two cells is positioned in a casing structure of the at least two casing structures. In some examples, the respective casing structure surrounds the respective cell with an opening on one end of the cell.