Expandable Cell-Isolation Pads for Battery Module Gas Blocking
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Solution Overview
Problem
In battery modules for electric and hybrid vehicles, local damage or events like fire or leakage in one battery cell can spread to other cells, potentially leading to module failure or explosion, as existing pads only absorb thickness changes without preventing event propagation.
Innovation Solution
Incorporating high-temperature, high-pressure gas-blocking pads made of flame-retardant materials that expand at predetermined temperatures, such as vermiculite or ceramic-based materials, to isolate affected battery cells and prevent gas spread, forming a barrier wall to contain events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pads are used between battery cells, then thickness changes due to tolerance are absorbed, but events such as fire or leakage in one battery cell can spread to other cells
Solution Approach 1:
The pad material undergoes a parameter change in response to temperature: it remains flexible at normal temperatures to absorb thickness variations, but expands in volume when temperature reaches a predetermined level to block gas paths and isolate affected battery cells. This temperature-dependent parameter change allows the same material to provide both thickness tolerance absorption and event propagation prevention.
Solution Approach 2:
The pad is constructed from composite materials that combine the properties of flexibility for thickness adjustment with temperature-responsive expansion capability. This composite structure enables the pad to perform dual functions: maintaining physical contact and absorbing dimensional variations under normal conditions, while forming a barrier wall to contain thermal and gas propagation when temperature increases occur.
2Ease of manufacture
If pads with only thickness absorption function are used, then manufacturing tolerance is accommodated, but no suppression of event spread occurs
Solution Approach 1:
The pad material provides self-service by automatically responding to temperature increases through volumetric expansion without requiring external control systems or additional components. When temperature reaches the predetermined level, the material inherently blocks gas paths and isolates affected cells, enabling the battery module to suppress event propagation using its own thermal response characteristics.
Solution Approach 2:
The pad is pre-configured with temperature-responsive expansion properties that activate before catastrophic failure occurs. By expanding at a predetermined temperature threshold, the pad creates a barrier wall in advance to prevent fire or leakage spread, addressing the harmful factor before it can propagate throughout the battery module.
3Reliability
If high-temperature expandable materials are incorporated in pads, then gas path blocking is achieved, but device complexity increases
Solution Approach 1:
The pad serves multiple functions simultaneously: it absorbs thickness variations during normal operation and blocks gas paths when temperature increases occur. This multi-functionality is achieved through a single component with temperature-responsive properties, eliminating the need for separate thickness adjustment mechanisms and gas barrier systems, thereby maintaining simplicity while enhancing reliability.
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 delays and suppresses the progression of events within the battery module by blocking gas paths and isolating affected cells, minimizing damage to other cells and preventing module-wide failures.
Implementation Method 1
the side pad includes a material which is flame retardant and expands in volume at a predetermined temperature or higher
Implementation Method 2
The material may include a mineral which expands in volume as internal moisture thereof is vaporized at the predetermined temperature or higher
Implementation Method 3
block a path along which a gas discharged from a battery cell in which an event occurs moves to a battery cell in which the event does not occur
Implementation Method 4
The side pad may further include a high-temperature curable material. The high-temperature curable material may include ceramic
Data Source
AI summary
Provided is a battery module including a pad having characteristics of expanding at a predetermined temperature or higher, thereby blocking a path along which a high-temperature, high-pressure gas discharged from the battery cell in which an event occurs moves, and thus, the gas is prevented from spreading to other battery cells.