Battery Cell Support Assembly With Thermal Event Venting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Battery cells in close proximity can experience thermal events due to heat build-up, leading to propagation of thermal energy between adjacent cells, potentially causing a chain reaction affecting the entire battery array.
Innovation Solution
A multi-cell rechargeable energy storage system (RESS) with a cell holder and thermal event passageways, featuring a sensor assembly that includes capacitive, temperature, and electromagnetic sensors to detect thermal events and potting material intrusion, integrated within a RESS enclosure to mitigate thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are arranged in close proximity to maximize energy density, then the productivity and space utilization are improved, but the risk of thermal propagation between adjacent cells increases
Solution Approach 1:
The battery array is segmented into isolated compartments by thermal barriers. Each battery cell or group of cells is separated from adjacent cells by these barriers, which physically divide the continuous space into discrete segments. This segmentation prevents thermal runaway from propagating from one cell to adjacent cells, thereby maintaining high energy density while reducing thermal propagation risk.
Solution Approach 2:
Thermal barriers serve as intermediary elements positioned between adjacent battery cells. These barriers act as mediators that intercept and block thermal energy transfer between cells. The barriers are strategically placed in the spaces between cells to provide thermal isolation, allowing cells to be arranged in close proximity while preventing harmful thermal propagation.
2Reliability
If thermal barriers are installed between battery cells to prevent thermal propagation, then the safety is improved, but the device complexity increases
Solution Approach 1:
The thermal barriers are designed to perform multiple functions simultaneously. They provide thermal isolation between cells, structural support for the battery array, and potential pathways for gas venting. By combining these functions into a single component, the overall structural complexity is minimized while maintaining high safety standards.
Solution Approach 2:
The thermal barriers are implemented as thin-walled structures or panels that provide effective thermal isolation without adding significant bulk or complexity. These thin film-like barriers are easily integrated into the battery assembly process and do not require complex manufacturing or installation procedures, thereby maintaining simplicity while improving safety.
3Quantity of substance
If aperture size is increased to improve gas venting, then the fluid flow is improved, but the structural integrity of the cell holder deteriorates
Solution Approach 1:
The gas venting function is moved from the cell holder apertures to dedicated thermal event passageways. These passageways provide large-dimensional pathways for gas flow that do not compromise the cell holder structure. By separating the venting function into a different dimensional space (through dedicated channels rather than holder apertures), both gas venting efficiency and structural integrity are maintained.
Solution Approach 2:
The thermal barriers with integrated passageways serve as intermediaries that handle gas venting separately from the cell holder structure. These barrier components with built-in venting channels mediate between the need for gas escape and the need for structural strength, allowing large effective venting areas without creating weak points in the cell holder.
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
Effectively detects and mitigates thermal events by alerting on potential intrusions and temperature changes, preventing the spread of high-temperature gases and debris, thereby safeguarding the battery system from chain reactions.
Implementation Method 1
The sensors include temperature sensors
Implementation Method 2
The sensor assembly includes capacitive sensors
Implementation Method 3
The sensor assembly includes at least one emitter and at least one receiver configured to receiver signals from the at least one emitter. The at least one emitter is located adjacent to a first end of a respective one of the thermal event passageways and the at least one receiver is located adjacent a second end of the respective one of the thermal event passageways
Implementation Method 4
Each aperture is configured to align with and be in fluid communication with the cell vent of one of the battery cells
Data Source
AI summary
A multi-cell rechargeable energy storage system (RESS) includes battery cells with each of the battery cell having a respective cell vent configured to expel gases. A cell holder is configured to support the battery cells and includes a holder body defining apertures arranged in rows. Each aperture is configured to align with and be in fluid communication with the cell vent of one of the battery cells. Thermal event passageways are located adjacent the cell holder with each thermal event passageway extending parallel to a respective row of apertures. A potting material at least partially surrounding the battery cells and a sensor assembly is in each of the thermal event passageways.