Battery Module Spacers for Thermal Runaway Containment
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Solution Overview
Problem
Existing lithium-ion batteries are susceptible to thermal runaway due to mechanical, electrical, and thermal abuse, leading to catastrophic failures such as fire or explosion, and current insulation materials fail to effectively contain heat and prevent propagation without compromising energy density or increasing module size and weight.
Innovation Solution
A multilayer thermal barrier material comprising aerogel compositions with alternating insulation and thermal capacitive layers, along with compressible and sacrificial layers, provides effective heat dissipation and containment while maintaining structural integrity and minimizing thickness and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal barriers are placed between adjacent battery cells to prevent thermal propagation, then thermal runaway propagation is reduced, but internal enclosure space is consumed
Solution Approach 1:
The patent employs thin film thermal barrier layers (spacers) positioned between adjacent battery cells. These thin films provide effective thermal isolation to prevent runaway propagation while occupying minimal space within the battery enclosure, thus resolving the contradiction between thermal safety and space utilization.
Solution Approach 2:
The thermal barrier spacers are constructed as composite structures combining different material layers with complementary properties. This composite approach maximizes thermal isolation effectiveness while minimizing the thickness and space occupied by the barriers, addressing both thermal safety and space constraints.
2Reliability
If vent channels are provided on the enclosure to release pressure from thermal runaway, then explosive decompression is prevented, but vent gases and ejecta may escape externally
Solution Approach 1:
The patent extracts and isolates the harmful vent gases and ejecta from the main battery enclosure by providing dedicated vent channels that direct these materials to specific containment areas. This separation prevents the harmful substances from escaping into the broader environment while maintaining pressure relief functionality.
Solution Approach 2:
The vent channels act as intermediary pathways between the battery cells and the external environment. These channels control and mediate the release process, directing vent gases and ejecta through designated routes rather than allowing uncontrolled escape, thus balancing pressure relief with harm containment.
3Reliability
If spacer elements contact the enclosure interior surface to form thermal barriers, then thermal propagation is blocked, but manufacturing alignment precision is required
Solution Approach 1:
The patent incorporates visual indicators (such as colored markers or contrasting features) on the spacer elements and corresponding contact points on the enclosure interior surface. These visual cues enable operators to easily verify proper alignment and contact during assembly, reducing the stringency of precision requirements and simplifying manufacturing quality control.
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 multilayer material effectively mitigates thermal propagation and fire hazards in lithium-ion batteries by maintaining temperature within safe ranges and accommodating cell swelling, without significantly impacting energy density or increasing module size and cost.
Implementation Method 1
each of the spacer elements comprising at least one thermal capacitive layer and at least one insulation layer; wherein at least the insulation portion of each of the spacer elements extends to contacts the interior surface of the enclosure such that a thermal barrier is formed between the adjacent battery cells
Implementation Method 2
each of the spacer elements comprising at least one thermal capacitive layer and at least one insulation layer
Data Source
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AI summary
The present disclosure relates to a battery module comprising: an enclosure comprising an interior surface, the interior surface defined by a first endplate and a second endplate extending between a first side wall and a second side wall and a top plate and a bottom plate, two or more battery cells disposed in the interior space of the enclosure; and one or more spacer elements disposed between adjacent battery cells, each of the spacer elements comprising at least one thermal capacitive layer and at least one insulation layer; wherein at least the insulation portion of each of the spacer elements extends to contacts the interior surface of the enclosure such that a thermal barrier is formed between the adjacent battery cells; wherein each of the spacer elements contact one or more channels formed on and/or in the interior surface: and wherein the one or more channels are substantially U-shaped having opposing sidewalls and a bottom surface.