Battery Array Venting and Delayed Cooling for Thermal Propagation

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Solution Overview

Problem

The close proximity of battery cells in a battery array increases the likelihood of degradation when one cell experiences thermal issues, and disconnecting the battery from power consumers does not effectively mitigate internal degradation.

Innovation Solution

Implementing a method where coolant flow to battery cells is delayed after detecting excessive temperature, allowing gases from a degraded cell to vent before increasing coolant flow, thereby reducing pressure and temperature within the battery, and using a dielectric liquid to cool adjacent cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If battery cells are positioned in close proximity to reduce battery size and increase efficiency, then battery compactness and power transfer efficiency are improved, but the risk of thermal propagation and degradation between adjacent cells increases

Engineering Contradiction:

Improvebattery sizeVSAvoidthermal propagation risk

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The battery array is segmented into multiple independent battery cell groups with physical separators between them. Each group can be independently cooled and monitored, preventing thermal propagation from one cell to adjacent cells while maintaining compact overall battery structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Dielectric liquid is introduced as an intermediary cooling medium that can safely contact battery cells without causing electrical short circuits. The liquid cooling system acts as a thermal mediator, transferring heat away from individual cells or groups before it can propagate to adjacent cells, thus enabling close cell proximity while managing thermal risk.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If coolant flow is immediately increased when temperature threshold is exceeded, then cooling efficiency is improved, but gas venting is hindered and pressure builds up within the battery

Engineering Contradiction:

Improvecooling efficiencyVSAvoidinternal pressure

Core Design Contradiction:

TemperatureVSStress or pressure

Solution Approach 1:

The system performs preliminary gas venting through pressure relief valves before initiating high-rate coolant flow. This preliminary action removes trapped gases that would otherwise form bubbles and impede coolant circulation, allowing subsequent cooling operations to proceed without pressure buildup while maintaining effective heat removal.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cooling system operates in periodic cycles: first venting phase to remove gases and equalize pressure, then cooling phase with increased coolant flow. This periodic operation pattern allows the system to alternate between pressure management and thermal management modes, achieving both goals effectively.

Inventive Principle:

Principle #19Periodic action

3Reliability

If disconnecting the battery from power consumers is used to reduce degradation possibility, then battery safety is improved, but internal degradation from thermal events cannot be prevented

Engineering Contradiction:

Improvebattery safetyVSAvoidinternal thermal degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system continuously monitors temperature, pressure, and cell voltage parameters in real-time. When thermal events are detected in individual cells or groups, the control system provides immediate feedback by activating targeted cooling and venting operations. This closed-loop feedback mechanism enables prevention of internal thermal degradation without requiring complete battery disconnection from the power system.

Inventive Principle:

Principle #23Feedback

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 approach reduces the risk of further battery cell degradation by venting gases and controlling pressure, enhancing cooling efficiency, and preventing thermal stress on adjacent cells.

Implementation Method 1

using a dielectric liquid to cool adjacent cells

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

venting gases and controlling pressure

Methodology Applied

Scientific EffectPressure relief: Depressurisation

Data Source

PatentUS20260048684A1System and method to reduce a thermal event of a battery array

Publication Date: 2026.02.19 FORD GLOBAL TECH LLC

AI summary

Systems and methods for reducing a possibility of propagated battery cell degradation are described. In one example, degradation of a battery cell may be determined via pressure or temperature. If degradation is detected, increased cooling of battery cells is held in abeyance to permit venting of gas generated via a battery so that thermal loading and pressures within the battery may be reduced.