Portable Battery Thermal Runaway Mitigation via Sacrificial Decomposition
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Solution Overview
Problem
There is a need for portable electrical energy storage devices that effectively manage the risk of electrical energy storage cell failure and combustion of gases produced as a result of such failure in multi-cell deployments, as well as the propagation of thermal energy to adjacent battery cells, and the hazard to users in the event of a rare failure event.
Innovation Solution
The implementation of sacrificial members within the portable electrical energy storage device that thermally decompose at elevated temperatures, creating channels for gases to escape, combined with thermal and elastic barriers to isolate and absorb thermal energy, and a burst structure to manage pressure and direct gases safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lithium-ion batteries are used for high energy density, then energy storage capacity is improved, but the risk of thermal runaway and combustion increases
Solution Approach 1:
The patent incorporates sacrificial members and thermal barriers into the battery structure before any failure occurs. These components are pre-positioned to automatically activate when thermal runaway begins, creating gas channels and blocking flame propagation paths in advance of actual combustion events.
Solution Approach 2:
The patent converts the harmful thermal energy and gas pressure from failing battery cells into beneficial effects by directing them through controlled pathways. The sacrificial members decompose to create escape routes for gases, and thermal barriers redirect heat away from adjacent cells, transforming dangerous thermal runaway energy into a controlled venting process that protects the battery pack.
2Reliability
If thermal barriers are added to prevent heat propagation, then safety is improved, but device complexity increases
Solution Approach 1:
The patent employs thin thermal barrier layers and flexible sacrificial members that can be integrated into existing battery cell structures. These components are designed as thin films or flexible elements that conform to battery geometries without requiring bulky additional structures, thereby maintaining relatively simple device architecture while providing effective thermal protection.
Solution Approach 2:
The sacrificial members are designed to undergo parameter changes at specific temperatures, transitioning from solid structural elements to decomposed materials that form gas channels. This temperature-triggered parameter change allows the same component to serve dual functions: providing structural support during normal operation and creating safety pathways during thermal events.
3Object-affected harmful factors
If sacrificial members are included to create gas channels, then combustion propagation is reduced, but manufacturing complexity increases
Solution Approach 1:
The sacrificial members are designed as disposable, low-cost components made from materials that decompose readily at elevated temperatures. These members are intentionally designed to be consumed during thermal events, transforming into gas channels that protect the battery pack. Their temporary, single-use nature allows for simpler material selection and manufacturing processes.
Solution Approach 2:
The patent utilizes composite material structures where sacrificial members are integrated with thermal barriers and battery cell components. These composites combine materials with different thermal properties and decomposition characteristics to achieve multiple functions simultaneously: structural support, thermal insulation, and controlled gas channel formation, thereby reducing the number of separate manufacturing steps.
4Object-affected harmful factors
If burst structures are added to manage pressure, then user safety is enhanced, but device complexity increases
Solution Approach 1:
The patent extracts and isolates the pressure management function into dedicated burst structures and venting pathways that are separated from the main battery cell structures. These extracted components are designed to handle pressure and gas flow independently, allowing the battery cells themselves to maintain their primary energy storage function without being burdened by safety management complexity.
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 solution reduces the risk of thermal runaway and combustion propagation, enhances user safety by containing and directing gases and heat away from sensitive areas, and maintains the structural integrity of the device during high-pressure events.
Implementation Method 1
The sacrificial member is formed of a material that does not thermally decompose when exposed to an environment below a first temperature and thermally decomposes when exposed to an environment at a second temperature greater than the first temperature
Implementation Method 2
a thermal energy absorbing material capable of absorbing thermal energy from a failed battery cell, preventing thermal runaway of adjacent battery cells
Implementation Method 3
an elastic material that protects terminals of battery cells from damage
Data Source
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AI summary
An electrical energy storage device for powering portable devices such as vehicles or consumer electronics includes barriers to minimize migration of thermal energy and propagation of combustion in the rare event that electrical energy storage cells fail, burst and ignite. Thermal energy absorbing materials are contained within the electrical energy storage device. Sacrificial members are provided within the thermal energy absorbing materials. In-situ channels are formed within the thermal energy absorbing materials when the sacrificial members thermally decompose.