Dual-Sheet Battery Cell Cover for Thermal Runaway Gas Diversion
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Solution Overview
Problem
Conventional venting systems in battery modules fail to effectively contain and manage venting gas streams during thermal runaway, leading to thermal propagation and potential thermal runaway in adjacent battery cells, posing a risk of fire and damage.
Innovation Solution
A dual-layer cover system comprising a thicker, heat-resistant first cover sheet and a thinner, heat-resistant second cover sheet, where the second sheet ruptures at the venting exit to divert venting gas streams away from adjacent cells, while the first sheet protects the cells from debris and maintains structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional venting system with a single cover sheet is used, then the structure is simple and easy to manufacture, but it fails to effectively contain and divert venting gas streams during thermal runaway, leading to thermal propagation to adjacent cells
Solution Approach 1:
The cover sheet is divided into two distinct layers: a first cover sheet with venting openings and a second cover sheet without venting openings. This segmentation allows each layer to perform specific functions - the first layer allows controlled venting while the second layer diverts the gas stream away from adjacent cells, resolving the contradiction between simplicity and effectiveness.
Solution Approach 2:
The solution transitions from a single two-dimensional cover sheet to a three-dimensional dual-layer structure with different thicknesses and configurations. The first cover sheet has venting openings while the second cover sheet is positioned to divert gas streams, adding a dimensional aspect to the venting system that enables effective thermal runaway management without excessive complexity.
2Object-affected harmful factors
If the cover sheet is made thicker to protect battery cells from venting gas streams and debris, then protection effectiveness is improved, but the pressure buildup during thermal runaway increases, preventing effective venting
Solution Approach 1:
The first cover sheet has venting openings at specific locations to allow pressure relief, while the second cover sheet is positioned to divert gas streams. This local differentiation of properties (openings vs. solid coverage, different thicknesses) enables the system to both protect cells and manage pressure buildup effectively during thermal runaway events.
Solution Approach 2:
The first cover sheet with venting openings acts as an intermediary between the battery cells and the external environment. It allows controlled pressure release while the second cover sheet mediates the direction of venting gas streams, preventing them from directly impacting adjacent cells while maintaining pressure management.
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
The dual-layer cover system effectively contains and diverts venting gas streams, preventing thermal propagation and protecting adjacent battery cells from thermal runaway, thereby enhancing safety and reducing the risk of fire.
Implementation Method 1
configured to rupture at a section opposite the venting exits due to the discharged venting gas stream exiting the covered venting exit
Data Source
AI summary
A battery system includes: a plurality of battery cells, each having a venting exit for discharging a venting gas stream at a venting side thereof; a first cover sheet having a first thickness covering the venting side of the battery cells to protect the battery cells from the venting gas stream discharged from an adjacent one of the battery cells and having venting openings aligned with the venting exits of the battery cells for letting the discharged venting gas stream pass therethrough; and a second cover sheet having a second thickness arranged between the first cover sheet and the plurality of battery cells to cover the venting exits of the battery cells. The second cover sheet being configured to rupture at a section opposite the venting exits due to the discharged venting gas stream exiting the covered venting exit, and the first thickness is larger than the second thickness.