Battery Pack Thermal Runaway Ducting With Flexible Vent Paths

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Solution Overview

Problem

Current thermal runaway protection systems for battery packs are not fluid-tight, allowing expanding potting compound to intrude into ducts or passageways, reducing their volume and impeding fluid flow, which compromises the effectiveness of fluid management during thermal runaway events.

Innovation Solution

A thermal runaway ducting system with flexible hoses and a sensor manifold, utilizing quick connect fittings for fluid communication between TRP trays, sensor manifold, and battery pack exit vent, along with features like solid particulate filters and filtering fin members to prevent solid particle entry and ensure fluid-tight connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If expanding potting compound is used for insulation, then thermal runaway propagation is prevented, but the compound intrudes into ducts and reduces passageway volume

Engineering Contradiction:

Improvethermal runaway protectionVSAvoidduct volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The system divides the insulation function from the ducting function by using separate TRP trays with integrated insulation materials, while ducts are configured to route around these trays, preventing compound intrusion into passageways

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The duct system acts as an intermediary that routes fluid away from TRP trays containing expanding potting compound, using strategic positioning and routing to prevent the compound from entering the duct passageways

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If insulating material is placed in TRP trays, then thermal propagation is blocked, but fluid flow paths become obstructed

Engineering Contradiction:

Improvethermal isolationVSAvoidfluid flow

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system segments the battery pack into distinct zones with TRP trays positioned to provide thermal isolation, while separate duct passageways are configured to maintain unobstructed fluid flow paths around these trays

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Insulation materials are placed locally within TRP trays at specific locations where thermal propagation risk is highest, while duct passageways are positioned in regions optimized for fluid flow, achieving both thermal protection and flow efficiency

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If rigid ducts are used for fluid routing, then structural stability is maintained, but manufacturing precision requirements increase

Engineering Contradiction:

Improveduct stabilityVSAvoidduct alignment

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The system uses flexible hoses instead of rigid ducts to route fluid between TRP trays and the battery pack, providing structural stability while accommodating manufacturing tolerances and assembly variations without requiring high precision alignment

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS20250286207A1Thermal runaway protection system for a battery pack

Publication Date: 2025.09.11 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

According to several aspects, a thermal runaway ducting system for a battery pack having one or more thermal runaway protection (TRP) trays is provided. The thermal runaway ducting system may include one or more flexible hoses in fluid communication with the one or more TRP trays. The thermal runaway ducting system further may include a sensor manifold in fluid communication with the one or more flexible hoses and a battery pack exit vent.