Hanging Battery Pack Barrier for Thermal Vent Containment
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Solution Overview
Problem
Existing traction battery packs in electrified vehicles face challenges in managing thermal events and vent byproducts, which can lead to increased thermal energy levels and potential venting of non-venting battery cells, necessitating improved thermal management and containment solutions.
Innovation Solution
The implementation of hanging barriers within the battery pack enclosure, featuring an attachment flange secured to the battery array and a foam pad with intumescent properties, which expands to contain and absorb thermal energy, along with endothermic fillers to suppress thermal events, while maintaining a spaced configuration to prevent vibration issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal barriers are placed close to battery cells to effectively contain thermal events, then thermal management effectiveness is improved, but vibration issues and potential contact with battery cells during vehicle operation worsen
Solution Approach 1:
The barrier transitions from a rigid structure to a flexible, conforming barrier that drapes over the battery cell stack. This dimensional change allows the barrier to maintain close proximity to cells for thermal containment while the flexible material absorbs vibration and prevents contact-induced damage.
Solution Approach 2:
The patent employs a flexible barrier material that can conform to the contours of battery cells and absorb mechanical vibrations. This flexible shell approach maintains thermal proximity without rigid contact, solving the contradiction between thermal effectiveness and vibration resistance.
2Reliability
If rigid thermal barriers are used to contain thermal events, then thermal containment is improved, but the barriers cannot conform to irregular battery cell shapes and may cause vibration damage
Solution Approach 1:
The flexible barrier material naturally conforms to irregular battery cell shapes without requiring complex rigid structures or multiple components. This single flexible element provides both thermal containment and geometric adaptability, reducing device complexity.
3Stability of the object's composition
If barriers are secured directly to battery cells to maintain stable positioning, then positioning stability is improved, but the securing process complicates manufacturing and may damage battery cells
Solution Approach 1:
The barrier uses a simple adhesive attachment method that is easy to apply during manufacturing. The adhesive provides sufficient holding strength for stable positioning without requiring complex mechanical fastening systems, simplifying the manufacturing process.
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 hanging barriers effectively contain and manage thermal events by absorbing and dissipating thermal energy, reducing the risk of secondary venting and enhancing overall thermal management within the battery pack.
Implementation Method 1
a foam pad with intumescent properties, which expands to contain and absorb thermal energy
Implementation Method 2
the foam pad includes an intumescent foam
Implementation Method 3
the foam pad includes a plurality of endothermic fillers
Data Source
AI summary
A traction battery pack assembly includes an enclosure, and a battery array within an interior of the enclosure. The battery array includes a plurality of battery cells. The assembly further includes a hanging barrier within the interior of the enclosure. The hanging barrier including an attachment flange that extends transversely from a hanging portion.