Battery Thermal Shield for Cell Venting and Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric vehicle battery packs are vulnerable to thermal runaway, where a failing cell can cause neighboring cells to overheat and short circuit due to hot vented gas, leading to a dangerous chain reaction.
Innovation Solution
A thermal shield made of flame and heat-resistant material, designed to act as a one-way valve, allows a failing cell to vent gases while protecting adjacent cells from the heat and gas, using a hexagonal frame for thermal isolation and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are packed tightly to increase energy density, then productivity is improved, but reliability deteriorates due to thermal runaway risk
Solution Approach 1:
The patent introduces thermal shields as separate protective components positioned between adjacent battery cells. These shields segment the thermal environment, creating isolated thermal zones that prevent heat propagation from one cell to another while maintaining tight cell spacing for high energy density.
Solution Approach 2:
The thermal shield acts as an intermediary barrier between neighboring battery cells. It intercepts and blocks hot vented gases and thermal radiation before they can reach adjacent cells, thereby mediating the thermal interaction between cells and preventing chain reactions.
2Reliability
If thermal shields are added to protect cells from hot gases, then reliability is improved, but device complexity increases
Solution Approach 1:
The thermal shield is constructed as a thin, flexible barrier that can conform to the contours of battery cells and packaging structures. This thin-film approach provides effective thermal protection while minimizing the added volume and structural complexity compared to rigid insulation barriers.
Solution Approach 2:
The thermal shield serves multiple functions simultaneously: it blocks hot gases, reduces thermal radiation, provides physical spacing between cells, and can serve as a mounting surface for other components. This multi-functionality reduces the need for separate protective components, thereby limiting the increase in device complexity.
3Reliability
If more material is used for thermal isolation, then reliability is improved, but weight increases
Solution Approach 1:
The thermal shield utilizes composite material structures that combine high thermal resistance with low density. By using advanced composite materials rather than traditional solid insulation, the patent achieves effective thermal isolation while minimizing the mass penalty.
Solution Approach 2:
The thin-film construction of the thermal shield provides adequate thermal protection with minimal material usage. The shield's thin profile significantly reduces the mass added to the battery pack compared to conventional thick insulation materials, while still effectively blocking hot gas and thermal radiation.
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 thermal shield effectively prevents neighboring cells from overheating and short circuiting by allowing safe venting of gases from a failing cell, enhancing safety and reducing material usage while maintaining energy density.
Implementation Method 1
The thermal shield acts as a one-way valve, allowing the cell experiencing thermal runaway to properly vent away hot gases, but still protecting the rest of the cells in the battery pack from the hot gases
Implementation Method 2
The hexagonal profile of the frame advantageously creates a thin air gap between the cells, utilizing the air gap as a thermal insulator
Data Source
AI summary
A battery assembly includes a thermal shield. The thermal shield protects battery cells in the battery assembly from hot gases vented by a neighboring cell experiencing thermal runaway. The thermal shield acts as a one-way valve, allowing the cell experiencing thermal runaway to properly vent away hot gases, but still protecting the rest of the cells in the battery pack from the hot gases.