Sealed Battery Pack Pressure Sensing for Thermal Runaway Containment
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Solution Overview
Problem
Lithium-ion battery systems face challenges with thermal runaway, leading to uncontrollable heat release, toxic gas propagation, and lack of timely notification for service personnel, posing risks to safety and equipment.
Innovation Solution
A sealed battery pack system with thermal runaway shield pouches containing thermally cooling fluid, pressure monitoring sensors, and a communication component to manage and alert personnel during thermal events, ensuring containment and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electronic temperature sensors are used to detect thermal runaway, then detection precision is improved, but the sensors and electronics fail quickly due to rapid heating
Solution Approach 1:
The patent introduces a sealed enclosure as an intermediary barrier between the battery module and the external environment. This enclosure contains the thermal runaway event internally, preventing direct exposure of external sensors to extreme temperatures. The pressure sensor detects pressure changes within the sealed enclosure, which serve as an indirect indicator of thermal runaway, allowing detection without exposing electronics to destructive heat.
2Temperature
If the battery system is open to ambient atmosphere, then heat dissipation is improved, but toxic gases propagate to harm service personnel
Solution Approach 1:
The patent extracts the toxic gas containment function from the open battery system by introducing a sealed enclosure. This enclosure captures and contains toxic gases generated during thermal runaway, preventing their propagation to the external environment and protecting service personnel. The sealed design allows the system to manage thermal events internally without releasing harmful substances externally.
3Object-affected harmful factors
If a sealed enclosure is used to contain toxic gases, then worker safety is improved, but pressure buildup occurs during thermal runaway
Solution Approach 1:
The patent implements a feedback mechanism where pressure sensors continuously monitor the pressure within the sealed enclosure. When pressure exceeds a predetermined threshold during thermal runaway, the system receives this feedback signal and activates the venting mechanism. This closed-loop control allows the system to maintain safety by dynamically responding to pressure conditions, ensuring the enclosure remains intact during normal operation but vents when necessary.
4Loss of time
If thermal runaway is allowed to proceed unchecked, then response time is improved, but catastrophic damage occurs
Solution Approach 1:
The patent implements preliminary protective actions by pre-installing thermal runaway shields, cooling fluids, and venting mechanisms within the battery system before thermal runaway occurs. When thermal runaway is detected through pressure changes, these pre-positioned components immediately activate to contain the event, cool the battery module, and prevent propagation to other modules. This preliminary preparation enables rapid response without requiring complex real-time decision-making during the thermal event.
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
Effectively mitigates thermal runaway by containing heat and toxic gases, preventing cascades, and promptly notifying personnel to manage and reset the system, ensuring worker safety and preventing damage.
Implementation Method 1
Each of the TRS pouches include a thermally cooling fluid that ruptures into the battery module from heat produced in a thermal runaway event in the battery module
Implementation Method 2
A pressure monitoring sensor detects an increase in air pressure within the sealed enclosure associated with gas released from the thermal runaway event
Data Source
AI summary
Provided in this disclosure is a battery pack system including battery modules each including battery cells. An air-tight, sealed enclosure retains the battery modules. A battery manager controls operation of each of the battery modules. One or more thermal runaway shield (TRS) pouches are associated with each of the battery modules. The TRS pouches include a thermally cooling fluid that ruptures into the battery module from heat produced in a thermal runaway event in the battery module. A pressure monitoring sensor detects an increase in air pressure within the sealed enclosure associated with gas released from the thermal runaway event in the battery cells in the battery modules. A communication component transmits a pressure signal from the pressure monitoring sensor to the battery manager for implementing a subsequent management step of the battery pack system.