Battery Pack Thermal Valve Assembly for Cell Vent Byproduct Control
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Solution Overview
Problem
Existing traction battery packs face challenges in effectively managing thermal energy and controlling the flow of battery cell vent byproducts, which can lead to thermal events and compromise the structural integrity of the battery pack.
Innovation Solution
The proposed traction battery pack incorporates a thermal management valve assembly with a pivotable thermal barrier that covers and uncovers vent openings in response to battery cell vent byproducts, and optionally includes a perforated section that ruptures to allow venting during thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a thermal management valve assembly with pivotable thermal barrier is used to control vent byproducts, then thermal energy transfer is blocked during normal conditions, but the device complexity increases
Solution Approach 1:
The thermal barrier is designed to be pivotable between a first position (blocking vent openings) and a second position (allowing vent byproducts to pass). This dynamic positioning allows the system to adapt to different operational conditions - blocking thermal energy during normal operation while allowing venting during thermal events, thus resolving the contradiction between blocking harmful thermal transfer and managing vent byproducts without requiring multiple static components
Solution Approach 2:
The thermal barrier utilizes the force from vent byproduct flow itself to pivot from the first position to the second position. When thermal events occur and vent byproducts flow through the vent openings, the force of this flow automatically moves the thermal barrier to uncover the openings, allowing the system to self-regulate without external control mechanisms, thereby reducing overall device complexity while maintaining effective thermal management
2Adaptability or versatility
If a perforated section is added to the thermal barrier to rupture during thermal events, then venting capability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The perforated section is pre-configured in the thermal barrier during manufacturing, with predetermined rupture characteristics. This preliminary preparation ensures that when thermal events occur, the perforated section will rupture at the appropriate moment to allow venting. The pre-designed rupture features eliminate the need for complex real-time decision-making mechanisms, maintaining manufacturing feasibility while ensuring reliable venting capability during thermal events
Solution Approach 2:
The thermal barrier has different properties in different regions - the perforated section is specifically designed with localized structural characteristics that make it susceptible to rupture under thermal stress, while the rest of the thermal barrier maintains its integrity and blocking function. This local differentiation allows the barrier to selectively rupture only where needed, balancing manufacturing precision requirements with effective venting capability
3Reliability
If thermal barriers are mounted to cross-member assembly using multiple attachment methods, then reliability of mounting is improved, but the ease of manufacture decreases
Solution Approach 1:
The upper attachment frame and lower attachment frame are integrated with the thermal barrier and mounting structure to form a unified assembly. This merging of components ensures that the thermal barrier is securely mounted to the cross-member assembly through multiple attachment points while maintaining ease of manufacture, as the integrated design allows for streamlined production processes compared to assembling multiple separate components
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 solution effectively blocks thermal energy transfer during normal conditions and controls the flow of vent byproducts during thermal events, thereby enhancing the structural integrity and safety of the traction battery pack.
Implementation Method 1
The thermal barriers are arranged to block the transfer of thermal energy from the cell stack to the cross-member assembly
Implementation Method 2
the thermal management valve assembly includes a thermal barrier having a perforated section that is configured to rupture in response to a flow of a battery cell vent byproduct against the thermal barrier
Data Source
AI summary
Thermal management valve assemblies are provided for use within traction battery packs. An exemplary thermal management valve assembly may be configured to block the transfer of thermal energy to adjacent structures inside the traction battery pack during normal operating conditions and may be further configured to control the flow of battery cell vent byproducts during battery thermal events. The thermal management valve assembly may include one or more attachment frames that can be mounted to a cell stack cross-member assembly, and one or more thermal barriers that can be connected to the attachment frame(s).