Battery Pack Thermal Barrier Layout for Runaway Containment
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Solution Overview
Problem
Secondary batteries are vulnerable to thermal events, particularly when crowded in small spaces, leading to potential thermal runaway and chain reactions, which can cause accidents such as fire or explosion, especially in medium to large devices like electric scooters or electric vehicles.
Innovation Solution
A battery pack design featuring a case with a bottom cover made of PBT or glass fiber material, a PCB protected by a barrier, a main frame with phase change material, and a barrier surrounding the PCB to block or delay external heat exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a plurality of battery cells are crowded in a small space to increase output and capacity, then productivity and energy density are improved, but thermal stability and safety deteriorate due to increased vulnerability to thermal events and chain reactions
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing a plurality of battery cells. This segmentation allows the system to maintain high capacity while isolating thermal events within individual modules, preventing chain reactions across the entire battery pack.
Solution Approach 2:
A barrier is introduced as an intermediary component between the battery cells and the PCB, and between adjacent battery modules. This barrier acts as a thermal insulator that blocks or delays heat transfer, protecting the PCB from thermal events while maintaining compact arrangement of battery cells.
2Volume of moving object
If battery cells are arranged in a compact configuration to reduce space occupation, then device size is reduced, but heat dissipation capability deteriorates leading to increased thermal runaway risk
Solution Approach 1:
Different regions of the battery pack are assigned different thermal management properties. The barrier provides localized thermal insulation where needed (between modules and around PCB), while heat dissipation channels are provided in other regions, creating a balanced thermal environment in compact space.
Solution Approach 2:
The barrier extends in multiple dimensions - vertically between battery cells and PCB, and horizontally between adjacent battery modules. This multi-dimensional arrangement enables effective thermal isolation without increasing the overall footprint of the battery pack.
3Ease of operation
If replaceable battery pack design is implemented for electric scooters to enable easy charging, then ease of operation is improved, but exposure to external impact and flame increases thermal event risk
Solution Approach 1:
The barrier is installed beforehand to protect the battery cells from external thermal events. This protective structure is in place before the battery pack is removed from the electric scooter, providing cushioning against flame and heat exposure during storage or replacement operations.
4Reliability
If thermal insulation barriers are added to protect battery cells from heat, then thermal stability is improved, but device complexity increases due to additional components
Solution Approach 1:
The barrier serves multiple functions simultaneously: it acts as a thermal insulator to block heat transfer, a physical barrier to prevent thermal propagation between modules, and a protective cover for the PCB. This multi-functionality reduces the need for separate components, thereby limiting the increase in overall device complexity.
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
Improves thermal stability and safety by blocking or delaying heat transfer to battery cells, reducing the risk of thermal events and accidents.
Implementation Method 1
a phase change material that fills an inside of the main frame
Implementation Method 2
the bottom cover may contain a PBT material or glass fiber material
Data Source
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AI summary
Disclosed is a battery pack. The battery pack includes a case having an open lower portion and providing an inner space; a bottom cover coupled to the lower portion of the case; a PCB accommodated within the case and positioned on the bottom cover; and a plurality of battery cells accommodated within the case and positioned on the PCB.