Battery Pack Beam-Coupled Cell Layout for Thermal Runaway Control
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Solution Overview
Problem
Conventional battery pack designs face challenges in heat dissipation, leading to potential thermal runaway, as tight cell placement increases heat transfer between adjacent cells, limiting the compactness and capacity of the pack.
Innovation Solution
The battery pack design incorporates thermal interface materials with higher conductivity than conventional insulation, laterally offset cell blocks, and bypass busbars to efficiently distribute heat away from failing cells, reducing heat transfer to adjacent cells and allowing for a more compact configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If tight cell placement is used to increase energy density, then the number of battery cells within the pack increases, but heat dissipation from the cells is impacted
Solution Approach 1:
The battery pack is divided into multiple cell blocks (first cell block, second cell block, third cell block) that are laterally offset from the center longitudinal axis. This segmentation allows heat to be distributed to different beams (first beam, second beam, third beam) rather than concentrating heat in adjacent cells, resolving the contradiction between tight placement and heat dissipation.
Solution Approach 2:
Different regions of the battery pack have different thermal management characteristics. Cell blocks are positioned at specific lateral offsets to create localized heat dissipation paths to different beams. The first cell block dissipates heat primarily to the first beam, while the second cell block dissipates heat to the second beam, allowing each region to manage its own heat locally.
2Reliability
If lateral offset configuration is used to improve heat distribution, then heat transfer to adjacent cells is reduced, but pack compactness may be affected
Solution Approach 1:
The patent introduces lateral offset positioning of cell blocks from the center longitudinal axis, adding a dimensional aspect to heat dissipation management. By positioning cell blocks at different lateral distances from the center, heat is directed to different beams in the lateral dimension, reducing heat transfer to adjacent cells while maintaining vertical stacking for compactness.
Solution Approach 2:
The structural beams serve dual functions: they provide mechanical support for the battery pack and act as thermal management pathways. The first beam, second beam, and third beam are both structural elements and heat dissipation conduits, merging structural and thermal functions to achieve compact design with effective heat distribution.
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 design effectively reduces heat transfer between cells, minimizing the risk of thermal runaway and enabling a more compact and robust battery pack with increased capacity by distributing heat to a greater portion of the pack, rather than just adjacent cells.
Implementation Method 1
a first interface material thermally coupling the first side surface of the first cell block with the first longitudinal beam
Implementation Method 2
an insulative material extending about the first cell block along at least one of the second side surface of the first cell block, the third side surface of the first cell block, and the fourth side surface of the first cell block
Data Source
AI summary
Battery packs according to some embodiments of the present technology may include a first longitudinal beam and a second longitudinal beam. The battery packs may include a plurality of cell blocks disposed between the first longitudinal beam and the second longitudinal beam. The plurality of cell blocks may include first and second cell blocks each characterized by a first side surface proximate the first longitudinal beam, a second side surface, a third side surface proximate the second longitudinal beam, and a fourth side surface. The battery packs may include a first interface material thermally coupling the first side surface of the first cell block with the first longitudinal beam. The battery packs may also include a second interface material thermally coupling the third side surface of the second cell block with the second longitudinal beam.