Multi-Module Battery Pack Thermal Barrier Design
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Solution Overview
Problem
High-voltage battery packs in vehicles are prone to thermal runaway, where heat quickly spreads between adjacent modules, leading to a higher risk of intermodular thermal runaway due to close proximity, which existing solutions fail to adequately mitigate.
Innovation Solution
A multi-module battery pack design incorporating a thermal barrier with a thickness of at least 1 mm and thermal conductivity of less than 4 W/m-K, arranged in heat transfer paths between adjacent modules, using materials like refractory ceramics and composite thermal spray coatings to block heat transfer and isolate thermal runaway events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery modules are positioned in close proximity to maximize space utilization, then vehicle interior space is freed up, but thermal runaway risk increases due to heat propagation between modules
Solution Approach 1:
The battery pack is divided into multiple modules with thermal barriers between them, segmenting the heat transfer paths. This allows modules to be positioned close together for space efficiency while the thermal barriers prevent heat propagation, thus resolving the contradiction between space utilization and thermal runaway risk
Solution Approach 2:
Thermal barrier materials are introduced as intermediary components between adjacent battery modules. These barriers physically separate the modules thermally while allowing them to remain in close proximity structurally, enabling both high space utilization and thermal safety
2Reliability
If thermal barrier thickness is increased to block heat transfer paths, then thermal runaway mitigation improves, but battery pack volume increases
Solution Approach 1:
Thermal barriers are applied locally at critical heat transfer paths between modules rather than uniformly throughout the entire battery pack. This targeted approach provides effective thermal runaway mitigation at the interfaces where heat propagation is most likely, while minimizing the overall volume increase of the battery pack
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 blocking heat transfer paths, reducing the risk of pack-wide thermal events and isolating the issue to individual modules, thereby enhancing safety and reliability of high-voltage battery systems.
Implementation Method 1
a thermal barrier arranged in one or more predefined heat transfer paths between adjacent battery modules... having a thickness of at least about 1 millimeter (mm) and a thermal conductivity of less than about 4 watts per meter Kelvin (W/m-K)... configured to block the heat transfer path(s)
Data Source
AI summary
A multi-module battery pack includes a battery tray defining multiple battery tray compartments, battery modules each disposed within a corresponding one of the compartments, and a thermal barrier arranged in a predefined heat transfer path through the tray between an adjacent pair of the battery modules. The thermal barrier has a thickness of at least about 1 mm and a thermal conductivity of less than about 4 W/m-K, such that the thermal barrier blocks the heat transfer path to mitigate a thermal runaway event of one of the adjacent pair of battery modules. An electric powertrain system includes a rotary electric machine having phase leads and an output member, a driven load coupled to the output member, and the multi-module battery pack. A method includes providing the tray, identifying the heat transfer path, and arranging the thermal barrier in the heat transfer path.