Battery Pack Cooling Control for Thermal Runaway Isolation

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Solution Overview

Problem

Battery thermal runaway can propagate heat to nearby cells, leading to a chain reaction and increased risk of additional cells entering thermal runaway, posing a significant challenge in vehicle electrical systems.

Innovation Solution

The implementation of thermal runaway mitigation systems, including cooling elements, heat shields, and vents, which expel coolant onto energy storage cells experiencing thermal runaway and direct hot gases away from other cells, thereby isolating and reducing the risk of propagation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the number of battery cells is increased to provide sufficient electricity, then the power output is improved, but the risk of thermal runaway propagation increases

Engineering Contradiction:

Improvepower outputVSAvoidthermal runaway propagation risk

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The battery pack is divided into multiple isolated modules, each with its own cooling system. When thermal runaway occurs in one module, the physical separation and independent cooling systems prevent heat propagation to other modules, allowing the battery to maintain higher power density without increasing overall thermal risk.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Coolant channels act as intermediary heat transfer media between battery cells and the external cooling system. The coolant absorbs excess heat from affected cells during thermal runaway events, preventing heat accumulation and propagation while allowing continued operation of unaffected cells.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If cooling elements are added to mitigate thermal runaway, then the safety is improved, but the device complexity increases

Engineering Contradiction:

ImprovesafetyVSAvoidcooling system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cooling system serves multiple functions: it cools battery cells during normal operation to maintain optimal temperature, and it actively mitigates thermal runaway events by directing coolant to affected cells. This multi-functionality reduces the need for separate safety systems, offsetting the added complexity with consolidated design benefits.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cooling system is designed to automatically respond to thermal runaway conditions without external intervention. Temperature sensors detect thermal runaway events and trigger increased coolant flow to affected areas, enabling the system to self-regulate and protect itself, reducing the need for complex external control systems.

Inventive Principle:

Principle #25Self-service

3Temperature

If coolant is expelled onto cells during thermal runaway, then the heat dissipation is improved, but the loss of coolant increases

Engineering Contradiction:

Improveheat dissipationVSAvoidcoolant loss

Core Design Contradiction:

TemperatureVSLoss of substance

Solution Approach 1:

The cooling system extracts and removes affected battery modules from the battery pack during thermal runaway events. This isolation prevents continued heat generation and allows the system to focus cooling resources on remaining healthy cells, reducing overall coolant consumption while maintaining effective heat dissipation where needed.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system pre-cools battery cells and maintains optimal temperature conditions before thermal runaway occurs. This preliminary cooling reduces the thermal energy available for runaway propagation, decreasing the amount of coolant needed during emergency mitigation and reducing overall coolant loss.

Inventive Principle:

Principle #10Preliminary action

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

This approach effectively mitigates the spread of thermal runaway, reducing the risk of further cell failures and enhancing the safety and reliability of battery systems in vehicles by isolating affected cells and dissipating heat effectively.

Implementation Method 1

a cooling element configured, in response to the cell entering thermal runaway, to expel coolant onto the cell

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 2

dissipating heat effectively

Methodology Applied

Scientific EffectHeat dissipation: Convection

Data Source

PatentUS12194887B1Control of cooling system for battery thermal mitigation

Publication Date: 2025.01.14 ZOOX INC

AI summary

A battery pack for a vehicle electrical system includes a casing for receiving one or more battery modules. The battery modules are insertable into a casing of the battery pack. Additionally, the battery modules may include cooling plate to cool the battery module and provide coolant to another battery module in response to a triggering event. Additionally, the battery modules may include a top cover with a frangible insulating material to further thermally insulate one battery module from another battery module and allow gasses and active material to escape the battery module in response to a triggering event. The battery pack may additionally be configured with vents for venting the gases and active material, such as those generated by a battery module in a thermal runaway event. Additionally, the battery modules may include a heat shield to direct vented gases and active material away from a cabin of a vehicle.