Compressed Pouch Cell Battery Structure for Thermal Runaway Containment
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Solution Overview
Problem
Batteries face thermal runaway issues due to catastrophic cell failures, which can lead to a domino effect of heat propagation and failure among adjacent cells, lacking solutions that balance thermal management with performance during normal operation.
Innovation Solution
A battery design featuring a metal can with compressed pouch cells and layered insulation and thermal conductors with fins, which applies pressure to enhance cycle life and prevent heat spread through thermal insulation and dissipation, while vent holes and intumescent paint aid in heat dissipation and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation layers are added between battery cells to prevent heat propagation, then thermal safety is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple functions into a single integrated structure: the thermal management system merges insulation, compression, and mechanical support functions into unified components. Insulation layers are integrated with compression springs and structural elements, eliminating the need for separate components and reducing overall system complexity while maintaining thermal safety.
Solution Approach 2:
The compression springs and structural components serve multiple functions simultaneously: they provide mechanical compression to maintain cell contact and performance, act as thermal insulation barriers, and provide structural support for the battery assembly. This multi-functionality reduces the number of separate components needed.
2Duration of action of stationary object
If compression pressure is applied to pouch cells to extend cycle life, then durability is improved, but cell deformation and manufacturing precision requirements increase
Solution Approach 1:
The patent uses compression springs instead of rigid compressive elements, allowing the system to dynamically adapt to cell expansion and contraction during charge-discharge cycles. The springs maintain consistent compression force while accommodating natural cell dimensional changes, reducing stress concentrations and deformation risks.
Solution Approach 2:
The compression force is optimized to specific parameter ranges that extend cycle life without causing deformation. The spring compression ratio and force are carefully controlled to remain within safe thresholds that prevent cell damage while maintaining sufficient pressure for performance.
3Temperature
If thermal conductors with fins are added to dissipate heat, then thermal management performance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The thermal conductors are integrated with existing structural components rather than being separate additions. Fins are attached to or formed as part of the battery housing and mounting structures, combining thermal management with mechanical support functions and simplifying the manufacturing process.
Solution Approach 2:
Thermal conductors with fins are strategically positioned at specific locations where heat generation is highest, such as near the cells and critical thermal zones. This localized approach provides effective heat dissipation where needed most without requiring thermal management components throughout the entire battery structure.
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 design effectively mitigates thermal runaway by slowing heat propagation and extending cycle life, ensuring safer and more efficient battery operation by maintaining pressure on cells and facilitating heat dissipation.
Implementation Method 1
A battery includes a metal can with a bottom, top opening and four sides. A plurality of pouch cells are stacked inside the metal can and the sides of the metal can are biased inward against the cells to provide compression.
Implementation Method 2
The cells are stacked with layers of insulation so that if one cell fails catastrophically, the released heat will not cause a neighboring cell to also fail.
Implementation Method 3
insulation and battery cells stacked with thermal conductors with double-sided fins
Implementation Method 4
thermal conductors with fins
Data Source
AI summary
A battery includes a metal can having a bottom, a top opening, and four sides. The battery also includes a plurality of cells stacked inside the metal can, wherein at least two opposing sides of the four sides of the metal can are biased inward against the plurality of cells to provide compression.