Battery Module Side-Wall Layout for Thermal Runaway Delay
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Solution Overview
Problem
Battery modules face safety risks and reduced cycle performance due to heat transfer issues between adjacent batteries during extreme situations like overcharge or short circuit, where thermal runaway can occur, affecting both safety and efficiency.
Innovation Solution
The design optimizes the area of the first side wall (S1) and the distance (D) between electrode assemblies of adjacent batteries, ensuring a balanced relationship of 1.2×10^-5 < D/S1 ≤ 500×10^-5 mm^-1, with a preferred range of 5×10^-5 < D/S1 ≤ 200×10^-5 mm^-1, to control heat dissipation and transfer effectively, using a first adhesive member with specific properties to connect the batteries and manage heat transfer efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the distance between electrode assemblies of adjacent batteries is reduced to increase energy density, then the productivity and space utilization are improved, but the heat dissipation performance deteriorates and thermal runaway risk increases
Solution Approach 1:
The case is designed with non-uniform wall thickness: the first side wall (facing adjacent batteries) has a thickness of 1-5mm providing thermal insulation, while the second side wall (facing external environment) has a thickness of 0.5-2mm for better heat dissipation. This local differentiation allows the battery to maintain compact dimensions for high energy density while providing targeted thermal management in different directions.
Solution Approach 2:
The case wall thickness is segmented into different regions with different thickness values. The first side wall is divided into multiple thickness zones (1-5mm) to create a thermal barrier between adjacent batteries, while the second side wall (0.5-2mm) allows more efficient heat release to the external environment. This segmentation enables simultaneous optimization of space utilization and thermal management.
2Temperature
If the area of the first side wall is increased to improve heat dissipation, then the temperature control is improved, but the volume of the battery increases reducing energy density
Solution Approach 1:
The case employs local quality differentiation with the first side wall having greater thickness (1-5mm) to provide thermal insulation where heat dissipation is needed, while the second side wall has smaller thickness (0.5-2mm) to minimize volume. This allows effective heat management through the first side wall without proportionally increasing the overall battery volume.
3Strength
If adhesive members are used to connect adjacent batteries, then the structural integrity is improved, but the heat transfer between batteries increases
Solution Approach 1:
The adhesive member's thermal conductivity is carefully controlled within the range of 0.2-0.5W/(m·K), which is higher than traditional adhesives but still relatively low. This parameter optimization allows the adhesive to provide sufficient mechanical bonding strength while limiting heat transfer between adjacent batteries, resolving the contradiction between structural integrity and thermal isolation.
4Productivity
If the distance between adjacent batteries is reduced, then the space utilization is improved, but the safety performance deteriorates due to increased thermal runaway risk
Solution Approach 1:
The case design implements local quality enhancement at the first side wall with increased thickness (1-5mm) specifically positioned between adjacent batteries. This creates a targeted thermal barrier that maintains compact battery spacing for high space utilization while providing sufficient thermal isolation to prevent thermal runaway propagation, thereby ensuring safety performance.
Solution Approach 2:
The thicker first side wall acts as a pre-established thermal cushion between adjacent batteries. In the event of thermal runaway in one battery, this thermal barrier provides beforehand protection by slowing heat transfer to adjacent batteries, buying time for safety systems to respond and preventing cascade failures, thus improving overall safety performance.
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 approach effectively postpones thermal runaway in adjacent batteries, enhancing both safety and cycle performance by regulating heat transfer and dissipation, while maintaining a balance between heat transfer efficiency and structural integrity.
Implementation Method 1
the area S1 of the first side wall and the distance D between the electrode assemblies of two adjacent batteries in the first direction satisfy a relationship: 1.2×10^-5 < D/S1 ≤ 500×10^-5 mm^-1
Implementation Method 2
a first adhesive member is positioned between two adjacent batteries and connects the first side walls of the two adjacent batteries
Data Source
Figure 1
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AI summary
The present invention provides a battery module, a battery pack and a vehicle. The battery pack comprises a box and a battery module, the battery module is accommodated in the box. The battery module comprises batteries sequentially arranged in a first direction. The battery comprises an electrode assembly, a case and a cap assembly, the electrode assembly is received in the case, and the cap assembly is connected with the case. The case comprises two first side walls, and the two first side walls are respectively positioned at two sides of the electrode assembly in the first direction. The first side walls of two adjacent batteries face each other. An area of the first side wall is defined as S1, a distance between the electrode assemblies of two adjacent batteries in the first direction is defined as D, S1 and D satisfying a relationship: 1.2×10−5mm−1≤D/S1≤500×10−5mm−1.