Structural Battery Side-Beam Venting for Thermal Runaway Exhaust
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Solution Overview
Problem
Battery packs in vehicles face thermal runaway issues due to failed battery cells, which can cause failure of additional cells due to hot gas, flames, and particulates, lacking effective venting mechanisms to manage such events.
Innovation Solution
A side beam structure with a venting chamber and integrated vents that fluidly connect battery cells to the exterior, including cell vents, pack vents, and optional baffles to manage and direct exhaust away from the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are integrated into a structural battery pack without venting mechanisms, then the structural integrity and energy density are improved, but thermal runaway can spread to additional cells due to hot gas, flames, and particulates
Solution Approach 1:
The venting chamber is segmented into multiple zones with baffles that divide the flow path, creating separate regions for different functions (venting, cooling, filtration). This segmentation allows the system to handle thermal runaway events more effectively by controlling the spread of hot gases and particulates while maintaining structural integrity.
Solution Approach 2:
The venting chamber acts as an intermediary space between the battery cells and the external environment. It includes baffles, filters, and cooling channels that mediate the thermal runaway event by filtering particulates, cooling hot gases, and directing flames away from adjacent cells before exhaust is released externally.
2Reliability
If a venting chamber with multiple vents and baffles is integrated into the side beam structure, then thermal runaway management is improved, but the device complexity increases
Solution Approach 1:
The venting chamber is merged with the side beam structure of the battery pack, combining structural support and thermal management functions into a single integrated component. The side beam serves dual purposes: providing mechanical strength to the battery pack and housing the venting chamber with its baffles and filters, thereby reducing overall system complexity.
Solution Approach 2:
The side beam structure is designed to perform multiple functions simultaneously: structural support, thermal runaway containment, gas filtration, and exhaust direction. This multi-functionality eliminates the need for separate dedicated venting components, reducing device complexity while maintaining effective thermal management.
3Object-affected harmful factors
If vents are positioned to direct exhaust away from the battery assembly, then the protection of adjacent cells is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The venting chamber incorporates localized features such as baffles and filters at specific positions to address thermal runaway management. The exhaust ports are strategically positioned and angled to direct hot gases and flames away from adjacent battery cells, with local structural modifications to achieve optimal flow direction without requiring extreme manufacturing precision across the entire structure.
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
The solution effectively directs hot gas, flames, and particulates from a failed cell away from the battery assembly, reducing the impact on adjacent cells and enhancing safety by isolating high-voltage bussing and providing structural support.
Implementation Method 1
A battery pack thermal runaway situation can occur when an individual cell inside the battery pack fails, such as due to physical impact during a vehicle collision or due to short circuit. During a thermal runaway event, failure of one battery cell can cause failure of additional battery cells, such as due to exposure of the additional battery cells to hot gas, flames, and particulates expelled from the failed battery cell.
Implementation Method 2
A first vent formed through the extruded member is configured to fluidly connect one or more battery cells of the battery assembly to the venting chamber and a second vent formed through the extruded member is configured to fluidly connect the venting chamber to an exterior of the vehicle. Thus, during thermal runaway of a battery cell, hot gas, flames, and/or particulates expelled from the failed battery cell are directed through the first vent and the venting chamber and out of the second vent away from the battery assembly
Data Source
AI summary
A vehicular rocker rail includes an extruded member configured for mounting at a vehicle equipped with the vehicular rocker rail. The extruded member includes a first side, a second side opposite the first side, and an upper side and a lower side respectively extending between the first side and the second side. The first side, with the extruded member mounted at the vehicle, extends along a battery cell of the vehicle. The extruded member defines a venting chamber. A cell vent is formed through the first side. The cell vent is configured to, with the extruded member mounted at the vehicle, fluidly connect the battery cell and the venting chamber. A pack vent is formed through the lower side. The pack vent is configured to, with the extruded member mounted at the vehicle, fluidly connect the venting chamber to an exterior of the vehicle at the lower side.