Battery Pack Resistor Discharge for Thermal Runaway Isolation
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Solution Overview
Problem
Battery packs face instability due to thermal runaway in battery modules, leading to increased temperatures, heat transfer, and potential ignition, causing accidents in large devices.
Innovation Solution
A battery pack design incorporating a resistor unit to convert electrical energy into thermal energy during thermal runaway, accompanied by a heat insulating member and a heat dissipating unit that connects to the pack housing to dissipate heat, preventing the propagation of thermal runaway between modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery modules are electrically connected to increase capacity and output, then energy storage capacity increases, but thermal runaway stability deteriorates
Solution Approach 1:
The battery pack is divided into multiple independent battery modules, each capable of being isolated from others. Thermal insulation structures are placed between modules to segment heat transfer paths, preventing thermal runaway propagation while maintaining high capacity through parallel connection of modules.
Solution Approach 2:
Thermal insulation structures act as intermediary elements between battery modules. These structures include insulating materials and air gaps that mediate heat transfer, blocking the direct transmission of thermal energy from one module to another, thus preventing cascaded thermal runaway while allowing electrical energy storage to be scaled.
2Reliability
If thermal insulation structures are added between battery modules, then thermal runaway propagation is prevented, but device complexity increases
Solution Approach 1:
The thermal insulation structures are designed to serve multiple functions: they provide thermal insulation between modules, act as mechanical spacers to maintain module positioning, and serve as mounting structures for cooling components. This multi-functionality reduces the need for separate dedicated components, thereby limiting the increase in device complexity while achieving thermal runaway prevention.
3Temperature
If heat dissipation structures are implemented, then heat accumulation is prevented, but manufacturing complexity increases
Solution Approach 1:
The heat dissipation structures are merged with existing thermal insulation components and module housings. Cooling channels are integrated into the insulation barriers between modules, and heat sinks are combined with the module mounting structures. This integration approach enables effective heat dissipation while avoiding the need for separate manufacturing processes for cooling components.
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 consumes electrical energy as thermal energy, preventing further thermal runaway and efficiently dissipating heat to prevent accumulation and adjacent module ignition.
Implementation Method 1
a resistor unit configured to convert electrical energy stored in the at least one battery module into thermal energy as a temperature inside the pack housing increases
Implementation Method 2
a heat insulating member surrounding at least a part of the resistor
Implementation Method 3
a heat dissipater configured to connect the heat insulating member to the pack housing
Implementation Method 4
dissipate the thermal energy through at least one of the pack housing and a heat sink
Data Source
AI summary
A battery pack includes: a plurality of battery modules; a pack housing in which the plurality of battery modules are accommodated; and an energy consumption unit accommodated inside the pack housing, connected to at least one of the plurality of battery modules, and configured to convert electrical energy stored in the battery module into thermal energy as a temperature inside the pack housing increases and dissipate the thermal energy through at least one of the pack housing and a heat sink.