Vehicle Battery Pack Heat Blocker Layout for Module Flame Isolation
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Solution Overview
Problem
In electric vehicle battery packs, ignition within the pack can lead to flames spreading to adjacent battery modules, causing thermal runaway and potential fires.
Innovation Solution
A battery pack design that includes a lower case and pack cover forming an accommodation space for battery modules, with inner members to separate the modules and a heat blocker between the pack cover and inner members to thermally isolate the modules and prevent flame spread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery modules are arranged closely to maximize space utilization, then productivity and space efficiency are improved, but heat transfer between modules increases and thermal runaway risk worsens
Solution Approach 1:
The battery pack is divided into multiple independent compartments using partition walls that extend from the lower case to the pack cover. These partition walls physically segment the accommodation space, creating isolated chambers for each battery module or group of modules. This segmentation prevents direct heat transfer and flame propagation between adjacent modules while maintaining efficient space utilization.
Solution Approach 2:
Heat blockers are introduced as intermediary thermal insulation components positioned between adjacent battery modules. These heat blockers act as thermal barriers that interrupt heat transfer pathways while allowing the modules to remain closely arranged. The heat blockers are integrated with the partition wall structure, creating an intermediate layer that provides thermal isolation without compromising space efficiency.
2Reliability
If partition walls extend fully from lower case to pack cover, then thermal isolation is improved, but device complexity and manufacturing difficulty worsen
Solution Approach 1:
The partition walls are designed with local quality variations: the lower portion extending from the lower case provides structural support and basic separation, while the upper portion integrates heat blockers for enhanced thermal isolation. This differentiated design allows the partition wall to fulfill multiple functions at different heights, improving thermal isolation where needed without unnecessarily complicating the entire structure.
Solution Approach 2:
The partition wall structure is merged with the heat blocker components to form an integrated assembly. The heat blockers are positioned and fixed to the partition walls, combining the structural separation function with the thermal isolation function in a single integrated structure. This merging reduces the number of separate components and simplifies manufacturing while maintaining effective thermal isolation.
3Reliability
If heat blockers are added between pack cover and inner members, then thermal isolation is improved, but device complexity and manufacturing cost worsen
Solution Approach 1:
The heat blockers are pre-positioned and fixed to the partition walls during the assembly process before the battery modules are installed. This preliminary action ensures that the thermal isolation structure is already in place and properly positioned, simplifying the overall assembly process and reducing the risk of installation errors. The heat blockers are integrated into the partition wall assembly, allowing them to be installed as a single unit rather than as separate components.
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 delays heat transfer between battery modules and prevents thermal runaway by structurally blocking the spread of flames, thereby enhancing safety and reliability of the battery pack.
Implementation Method 1
a heat blocker provided between the pack cover and the plurality of inner members so as to thermally isolate the plurality of battery modules separated by the plurality of inner members
Data Source
AI summary
A battery pack for a vehicle may include: a plurality of battery modules arranged on a plane; a lower case forming an accommodation space surrounding the lower and lateral portions of the plurality of battery modules; a pack cover coupled to the upper portion of the lower case so as to cover the upper portion of the accommodation space; a plurality of inner members provided in the accommodation space to separate the plurality of battery modules; and a heat blocker provided between the pack cover and the inner members so as to thermally isolate the battery modules separated by the inner members.