Battery Pack Thermal Runaway Prevention via Localized Resin
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Solution Overview
Problem
Existing battery packs face challenges in efficiently preventing thermal runaway induction among cylindrical cells due to difficulties in achieving a stable thermally coupled state between cells and thermally conductive resin, leading to inefficiencies in manufacturing and increased risk of energy escalation during thermal events.
Innovation Solution
A battery pack design featuring a battery holder with partition walls and a thermally conductive resin applied between adjacent cylindrical cells, ensuring a closely adhered, thermally coupled state, which effectively absorbs and radiates thermal energy, preventing thermal runaway induction while allowing for efficient mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermally conductive resin is filled into the entire exterior case and cylindrical cells are buried in the resin, then thermal energy absorption is improved, but manufacturing time and effort increase significantly
Solution Approach 1:
The invention extracts the thermally conductive resin from the entire exterior case and concentrates it only at the necessary locations between adjacent cylindrical cells. This selective placement maintains thermal energy absorption functionality while dramatically reducing the amount of resin needed and simplifying the manufacturing process.
Solution Approach 2:
The invention applies local quality by placing thermally conductive resin only in specific locations where thermal coupling is needed - between adjacent cylindrical cells - rather than uniformly throughout the entire case. This targeted approach optimizes thermal management where it matters most while reducing overall material usage and manufacturing complexity.
2Reliability
If thermally conductive resin is injected into the exterior case, then thermal coupling is achieved, but air pockets remain and degrade thermal coupling stability
Solution Approach 1:
The invention segments the application of thermally conductive resin into discrete locations between individual cylindrical cells rather than attempting a single comprehensive injection into the entire case. This segmented approach eliminates air pocket formation by treating each cell interface separately, ensuring complete thermal coupling at each location.
Solution Approach 2:
The invention employs preliminary action by pre-positioning cylindrical cells in the battery holder at fixed locations before applying thermally conductive resin. This predetermined arrangement ensures proper spacing and alignment, allowing precise resin application without air pockets and eliminating the need for complex air exhaustion processes.
3Reliability
If fluid thermally conductive resin is used to dip cylindrical cells, then thermal coupling is achieved, but resin leakage occurs and workability decreases
Solution Approach 1:
The invention extracts the dipping process and replaces it with a controlled application method where thermally conductive resin is applied only at specific locations between cells. This eliminates the resin leakage problem inherent in dipping fluid resin while maintaining effective thermal coupling.
Solution Approach 2:
The invention changes the physical state parameter of the thermally conductive resin from fluid (for dipping) to a more controlled application form. This parameter change allows precise placement of resin between cells without the uncontrolled flow and leakage that occurs with fluid dipping, significantly improving workability.
4Reliability
If bottom case is molded in a bottomed dish shape to prevent resin leakage, then resin containment is improved, but production efficiency decreases due to required rest time
Solution Approach 1:
The invention extracts the resin containment function from the bottom case structure and implements it through localized application between cells. This eliminates the need for a bottomed dish shape and associated rest time requirements, enabling continuous mass production while maintaining resin containment.
Solution Approach 2:
The invention uses preliminary action by pre-positioning cells and applying resin in a controlled sequence before any leakage can occur. This predetermined process arrangement eliminates the need for post-application rest time and special case shaping, enabling efficient continuous production.
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 solution ensures effective prevention of thermal runaway induction by maintaining an ideal thermally coupled state between cells, enhancing safety and enabling cost-effective, efficient mass production by simplifying the manufacturing process and improving heat radiation characteristics.
Implementation Method 1
thermally conductive resin 7 that closely adheres to the cylindrical cells, which are stored in the battery holder, in a thermally coupled state above the battery holder
Implementation Method 2
the thermal energy of cylindrical cells 1 cannot be certainly and stably transferred to thermally conductive resin 87
Data Source
AI summary
Battery pack includes: a plurality of chargeable/dischargeable cylindrical cells; battery holder in which the plurality of cylindrical cells are disposed; and thermally conductive resin that closely adheres to cylindrical cells, which are stored in battery holder, in a thermally coupled state above battery holder. Battery holder includes: bottom plate including a plurality of holding grooves in which cylindrical cells are disposed; and partition walls that are disposed between holding grooves and between adjacent cylindrical cells. Partition walls are lower than the diameter of cylindrical cells disposed in holding grooves, thermally conductive resin is disposed between adjacent cylindrical cells above partition walls, and thermally conductive resin interconnects adjacent cylindrical cells.