Battery Module Layer Structure for Thermal Runaway Containment
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Solution Overview
Problem
Existing battery modules face high risks of thermal runaway due to rapid heat transfer between cells, leading to uncontrolled temperature increases and potential fire hazards.
Innovation Solution
The battery module design incorporates alternating layers of thermal insulating and high conductive materials between cells and lateral walls to manage heat transfer, redirecting heat away from adjacent cells and reducing the risk of thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cells are separated only by insulating walls, then heat transfer between cells is reduced, but heat cannot be dissipated effectively leading to temperature buildup
Solution Approach 1:
The patent applies different thermal properties to different regions of the same structure. Insulating walls are placed between adjacent cells to block lateral heat transfer, while high conductive layers are placed between cells and lateral walls to conduct heat away from cell centers. This local differentiation of thermal properties allows simultaneous heat isolation and heat dissipation.
Solution Approach 2:
The battery module uses a composite thermal management structure combining two materials with opposite thermal characteristics: insulating materials (low thermal conductivity) and highly conductive materials (high thermal conductivity). This composite approach creates a thermal management system that can both isolate and conduct heat as needed in different locations.
2Temperature
If high conductive layers are used between all cells and lateral walls, then heat dissipation is improved, but heat spreads more easily to adjacent cells
Solution Approach 1:
The patent applies different thermal properties to different regions of the same structure. Insulating walls are placed between adjacent cells to block lateral heat transfer, while high conductive layers are placed between cells and lateral walls to conduct heat away from cell centers. This local differentiation of thermal properties allows simultaneous heat isolation and heat dissipation.
Solution Approach 2:
The insulating walls act as intermediary elements between cells, blocking the direct thermal path that would allow heat to spread from one cell to adjacent cells. The high conductive layers serve as intermediary heat sinks that capture heat from cells and redirect it toward lateral walls for dissipation, rather than allowing direct cell-to-cell transfer.
3Object-affected harmful factors
If alternating insulating and conductive layers are used, then heat transfer to adjacent cells is limited, but some heat is carried to distant cells which may create new thermal risks
Solution Approach 1:
The thermal management system is segmented into multiple functional zones: insulating walls segment the space between adjacent cells to block heat transfer, while alternating conductive layers create segmented heat dissipation paths that carry heat laterally away from cell centers. This segmentation creates multiple thermal zones with different functions.
Solution Approach 2:
The patent converts the potentially harmful effect of heat carry-over to distant cells into a beneficial thermal distribution pattern. By using alternating conductive layers, heat that would otherwise concentrate in adjacent cells is instead distributed laterally to lateral walls where it can be safely dissipated, transforming a thermal management challenge into an effective heat dissipation mechanism.
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
This design effectively limits the spread of heat, preventing overheating and reducing the likelihood of thermal runaway, thereby enhancing safety and stability.
Implementation Method 1
each cell being separated from adjacent cells by respective insulating walls
Implementation Method 2
each end cell is separated from at least one of the two lateral walls by a high conductive layer
Data Source
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AI summary
The battery module (10) comprises a plurality of cells (12) aligned in an alignment direction (X), the plurality of cells comprising two end cells (12A) and intermediate cells aligned between the end cells (12A) in the alignment direction (X), each cell (12) being separated from adjacent cells by respective insulating walls (28), the battery module (10) also comprising two lateral walls (14a, 14b). Each end cell (12A) is separated from at least one of the two lateral walls (14a, 14b) by a high conductive layer (34), the cells (12) being separated from the same lateral wall by an insulating layer (32) or a high conductive layer (34), by alternating from a conductive layer (34) and an insulating layer (32) from any cell (12) to adjacent cells (12).