Battery Module Sprinkler Cover for Rapid Thermal Runaway Cooling
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Solution Overview
Problem
Existing battery modules face challenges in rapidly removing insulation covers to allow smooth injection of cooling fluid when high-temperature venting gases are leaked, which can lead to ignition and explosion due to rapid temperature increases.
Innovation Solution
A battery module structure with a sprinkler system that includes a coupler, sprinkler head, and insulation cover, where the insulation cover is designed to detach at elevated temperatures, allowing unobstructed cooling fluid injection, and an expansion pad to contain the fluid within the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation cover is provided to the sprinkler head, then the sprinkler system is protected from external factors, but the insulation cover obstructs the injection of cooling fluid when thermal runaway occurs
Solution Approach 1:
The insulation cover is pre-configured with a temperature-responsive bonding layer that automatically detaches when exposed to high temperatures during thermal runaway. This preliminary setup ensures that the cover provides protection during normal operation but automatically removes the obstruction when cooling is urgently needed, resolving the contradiction between protection and rapid fluid injection.
Solution Approach 2:
The bonding layer's physical state changes in response to temperature parameter changes. At normal temperatures, the bonding layer maintains the cover's protective function. When temperature exceeds a threshold during thermal runaway, the bonding layer's adhesive properties change, causing the cover to detach and allow rapid cooling fluid injection.
2Stability of the object's composition
If the insulation cover remains attached during thermal runaway, then the sprinkler structure remains intact, but the cooling fluid injection is delayed and obstructed
Solution Approach 1:
The temperature-responsive bonding layer is pre-installed on the insulation cover, creating a preliminary mechanism that automatically activates during thermal runaway. This ensures the cover maintains structural integrity during normal operation but automatically detaches at the critical moment when cooling is needed, minimizing time loss without compromising structural stability during non-critical periods.
Solution Approach 2:
The bonding layer acts as a temporary coupling mechanism that can be replicated or replaced. It provides the necessary structural connection during normal operation but is designed to fail in a controlled manner during thermal runaway, allowing the cover to detach and enabling rapid cooling fluid injection without permanent damage to the sprinkler structure.
3Productivity
If a temperature-responsive bonding layer is used to attach the insulation cover, then the cover automatically detaches during thermal runaway, but the bonding layer may fail to detach at the correct temperature
Solution Approach 1:
The bonding layer is specifically selected or engineered to undergo a phase change or adhesive property change at a predetermined temperature threshold. This parameter-based response ensures reliable and consistent detachment behavior during thermal runaway events, allowing automatic cover removal at the correct temperature without manual intervention.
Solution Approach 2:
The bonding layer is designed as a sacrificial, single-use component that is inexpensive but critical for the system's safety function. It is intended to fail in a controlled manner during thermal runaway events, providing reliable automatic cover detachment. The bonding layer's temporary nature allows it to be replaced or regenerated without affecting the permanent structural components of the sprinkler system.
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
Enables rapid cooling and fire extinguishing by ensuring uninterrupted cooling fluid injection and containment within the module, preventing thermal runaway and explosion.
Implementation Method 1
configured to be separated from the fixing portion when a temperature in the module housing exceeds a reference temperature as a bonding force of the bonding layer is decreased or lost
Implementation Method 2
a cooling fluid for fire extinguishing and cooling is smoothly injected
Data Source
AI summary
A battery module includes a plurality of battery cells; a module housing configured to accommodate a cell stack including the plurality of battery cells; and a sprinkler provided through the module housing at one side of the cell stack in a stacking direction, and the sprinkler includes a coupler positioned at an outer side of the module housing and connected to a supply tube that supplies a cooling fluid; a sprinkler head positioned at an inner side of the module housing and connected to the coupler; and an insulation cover including a fixing portion fixed to the module housing and a cover portion fixed to the fixing portion by a bonding layer to cover the sprinkler head and configured to be separated from the fixing portion over a reference temperature as a bonding force of the bonding layer is decreased or lost.