Battery Pack Thermal Runaway Mitigation via Cell Isolation
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Solution Overview
Problem
Existing electric vehicle battery packs face challenges with thermal runaway propagation, leading to reduced longevity and feasibility due to inefficient heat management systems, which can cause overheating and damage to adjacent cells, necessitating a more effective solution to prevent thermal runaway events.
Innovation Solution
A multi-cell battery pack system that incorporates active and passive cooling mechanisms, including thermally conductive compounds, aluminum cooling tubes, and sensors to detect overheating conditions, allowing for controlled temperature management and isolation of overheating cells to prevent thermal runaway, while also utilizing a vehicle's HVAC system for heat regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If heavy high voltage battery systems are used to achieve long range, then the vehicle range is improved, but the vehicle weight increases and acceleration performance deteriorates
Solution Approach 1:
The battery pack is divided into multiple individual cells, each with its own temperature monitoring and protection mechanisms. This segmentation allows for targeted thermal management of specific cells without requiring heavy cooling infrastructure for the entire pack, reducing overall system weight while maintaining long-range capability.
Solution Approach 2:
The system performs preliminary thermal management by monitoring cell temperatures and adjusting operation before thermal runaway occurs. The microcontroller proactively balances cell temperatures and prevents overheating conditions, allowing the use of lighter battery components without compromising safety or range.
2Power
If batteries operate at high power output, then the vehicle performance is improved, but the battery temperature increases and longevity deteriorates
Solution Approach 1:
The system continuously monitors cell voltages and temperatures, providing real-time feedback to the microcontroller. Based on this feedback, the system dynamically adjusts power output and activates cooling measures when temperature thresholds are approached, enabling high power operation without excessive temperature rise that would reduce longevity.
Solution Approach 2:
The system changes operating parameters such as current draw and voltage distribution based on real-time temperature conditions. When cells approach unsafe temperatures during high power output, the microcontroller modifies operational parameters to reduce heat generation, maintaining both performance and longevity.
3Temperature
If air cooled systems are used to remove heat from batteries, then the battery temperature is reduced, but the system efficiency deteriorates due to overheating or overcooling
Solution Approach 1:
The cooling system transitions from static air cooling to dynamic liquid cooling with active flow control. The system dynamically adjusts coolant flow rates based on real-time temperature measurements, providing precise thermal management that prevents both overheating and overcooling, thereby improving energy efficiency compared to conventional air cooling systems.
Solution Approach 2:
The system employs liquid coolant circulation through channels in the battery pack, replacing inefficient air cooling. This hydraulic cooling system provides superior heat transfer efficiency and allows for precise temperature control, reducing energy losses associated with inadequate cooling while preventing overcooling conditions.
4Reliability
If one battery cell overheats, then thermal runaway propagates to the entire battery pack, but the battery longevity and charge holding ability deteriorates
Solution Approach 1:
The system electrically isolates individual cells or groups of cells from the main battery pack through switches controlled by the microcontroller. When a cell shows signs of thermal runaway, it is extracted from the electrical circuit, preventing propagation to other cells while preserving the functionality of the remaining battery pack, thus maintaining overall longevity.
Solution Approach 2:
The system implements protective measures before thermal runaway occurs by continuously monitoring cell conditions and activating cooling or isolation protocols at early warning stages. This beforehand cushioning prevents full thermal runaway events, preserving battery longevity while ensuring safety.
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 system effectively mitigates thermal runaway events by actively and passively managing temperature, increasing the longevity and performance of the battery pack, preventing overheating propagation, and ensuring safe operation of electric vehicles by maintaining optimal cell temperatures and isolating overheating cells.
Implementation Method 1
The cells are arranged in an array in space and a thermally conductive compound is used to fill space between the cells
Implementation Method 2
aluminum cooling tubes, and sensors to detect overheating conditions, allowing for controlled temperature management
Implementation Method 3
utilizing a vehicle's HVAC system for heat regulation
Data Source
Figure 1~2
Figure 3a~4
Figure 5~7
AI summary
A method of mitigating propagation of a thermal event in an energy storage system having a plurality of cells is disclosed. The method includes the steps of identifying the heat sources within the energy storage system and plurality of cells. The method then controls a temperature of the energy storage system and plurality of cells and also detects predetermined conditions within the energy storage system. The method then performs a predetermined action based on when one of the predetermined conditions is detected. A plurality of sensors and switches along with associated hardware or software will be used to control the temperature of the energy storage system upon detection of predetermined conditions involving overheating, over current, over voltage of the like.