Battery Module Venting With Phase Change Layer for Thermal Runaway
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Solution Overview
Problem
Existing battery modules and packs face challenges in managing thermal runaway and heat dissipation, leading to potential ignition and explosion due to uncontrolled high-temperature gas ejection and thermal propagation between battery cells.
Innovation Solution
Incorporation of a phase change material layer with a mesh structure between battery cells and a module frame, along with venting holes in the frame and busbar frame, to guide high-temperature gas and flame in a specific direction, while the phase change material delays thermal runaway by melting and extinguishing fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple battery modules are concentratedly disposed to increase mileage, then productivity and energy capacity are improved, but thermal runaway propagation risk increases
Solution Approach 1:
The patent divides the battery module into segmented compartments using partition walls and heat insulating material layers between individual battery cells. This segmentation isolates thermal runaway events to specific cells or modules, preventing propagation to adjacent cells while maintaining high energy density through optimized spatial arrangement.
Solution Approach 2:
The patent introduces heat insulating material layers and partition walls as intermediary elements between battery cells. These intermediaries act as thermal barriers that block heat transfer and flame propagation pathways, allowing close packing of cells for high capacity while maintaining thermal safety through controlled thermal isolation.
2Power
If battery cells are stacked in a confined space to improve output, then power density is improved, but heat dissipation becomes difficult
Solution Approach 1:
The patent employs thin heat insulating material layers and flexible partition structures that can be positioned in narrow gaps between battery cells. These thin films provide effective thermal isolation without consuming significant space, enabling high power density through compact cell stacking while maintaining thermal management capability.
Solution Approach 2:
The patent utilizes porous heat insulating materials that provide high thermal resistance while maintaining low density and allowing heat dissipation pathways. The porous structure enables thermal isolation between cells while permitting controlled heat transfer to cooling systems, resolving the conflict between compact stacking and heat dissipation.
3Reliability
If thermal insulating material is disposed between battery cells to delay thermal runaway, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated structures: partition walls serve both as structural support elements and thermal isolation barriers, while heat insulating material layers simultaneously provide thermal protection and cell spacing. This merging reduces the number of separate components and simplifies assembly while maintaining thermal safety functionality.
Solution Approach 2:
The patent designs partition walls and structural elements to serve multiple purposes: mechanical support, thermal isolation, flame blocking, and spatial organization. This multi-functionality reduces overall device complexity by eliminating the need for separate dedicated thermal management components, achieving reliable thermal runaway prevention through integrated design.
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 directs high-temperature gas and flame away from the battery module, minimizing thermal propagation and delaying or preventing ignition, thus enhancing safety and stability.
Implementation Method 1
a phase change material layer with a mesh structure between battery cells and a module frame
Implementation Method 2
the phase change material delays thermal runaway by melting and extinguishing fires
Implementation Method 3
venting holes in the frame and busbar frame, to guide high-temperature gas and flame in a specific direction
Data Source
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AI summary
A battery module according to an embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked; a module frame that houses the battery cell stack; and a phase change material layer that is located between the battery cell stack and the module frame, wherein the phase change material layer includes a phase change material and has a mesh structure, and wherein the module frame is formed with venting holes.