Expandable Thermal Barrier Assembly for Battery Vent Byproduct Blocking
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Solution Overview
Problem
Existing thermal barrier systems in traction battery packs are inadequate in managing thermal energy and preventing the cascading of vent byproducts from one battery cell to another, leading to potential thermal runaway.
Innovation Solution
A thermal barrier assembly with an expandable element, such as a foam, that expands to shield areas from vent byproducts, using a frame with a H-shaped cross-section and a mica shield to redirect and block the flow of vent byproducts, and optionally incorporating a biasing member and sealing assembly to enhance protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid thermal barrier structure is used, then structural strength is improved, but adaptability to thermal expansion and gap sealing deteriorates
Solution Approach 1:
The patent employs a biasing member (spring) that transforms the rigid barrier structure into a dynamic system. The spring allows the barrier to adapt its position and sealing force in response to thermal expansion and contraction, maintaining contact with the enclosure wall while accommodating dimensional changes during battery operation.
Solution Approach 2:
The biasing member changes its mechanical parameters (force, position) in response to thermal conditions. As the battery and enclosure expand or contract with temperature changes, the spring adjusts its compression state, maintaining optimal sealing pressure without requiring complex active control systems.
2Ease of manufacture
If a fixed thermal barrier is used, then manufacturing simplicity is improved, but effectiveness in blocking vent byproducts deteriorates
Solution Approach 1:
The barrier assembly incorporates a spring-loaded mechanism that automatically activates during venting events. The biasing member stores mechanical energy during normal operation and releases it when the barrier is displaced by vent byproducts, ensuring reliable sealing without complex sensors or active control systems.
Solution Approach 2:
The biasing member provides self-actuating functionality - it automatically pushes the barrier against the enclosure wall when venting occurs, using the force generated by the spring's compression. This eliminates the need for external actuators, sensors, or control systems while maintaining reliable protection.
3Temperature
If thermal barrier material is placed close to battery cells, then thermal protection is improved, but risk of damage from vent byproducts increases
Solution Approach 1:
The barrier assembly acts as an intermediary element positioned between the battery cells and the enclosure wall. It provides thermal insulation while protecting the enclosure structure from direct exposure to vent byproducts, effectively mediating between the heat-generating cells and the protective enclosure.
Solution Approach 2:
The barrier material is strategically positioned at critical locations where vent byproducts are most likely to escape and cause damage. The assembly provides localized protection at array terminals and enclosure interfaces rather than requiring uniform protection throughout the entire battery pack.
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 manages thermal energy and prevents the spread of vent byproducts, reducing the likelihood of cascading thermal events by redirecting and blocking vent byproducts, thereby maintaining battery pack stability.
Implementation Method 1
an expandable element secured to the frame, the expandable element configured to expand against a structure in response to a battery cell venting event
Implementation Method 2
a biasing member and a sealing assembly, the biasing member configured to bias the sealing assembly against the structure
Data Source
AI summary
A thermal barrier assembly for a traction battery pack includes a frame extending longitudinally along an axis, and an expandable element secured to the frame. The expandable element is configured to expand against a structure in response to a battery cell venting event to block vent byproducts from flowing through a gap between the structure and the frame.