Cooler Beam Battery Pack Layout for Thermal Runaway Containment
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Solution Overview
Problem
Conventional battery systems face challenges in preventing thermal propagation during thermal runaway events, which can lead to destructive consequences such as fires and damage to the battery pack.
Innovation Solution
The implementation of a battery system that includes cooler beams and a channel system to guide coolant, providing thermal insulation and actively cooling the cells to prevent or slow down thermal propagation, combined with a detection system to activate cooling measures during thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery systems are used without specialized cooling structures, then the device complexity is reduced, but thermal propagation during thermal runaway events cannot be prevented
Solution Approach 1:
The cooler beam serves multiple functions: it acts as a structural support element for the battery pack and simultaneously functions as a thermal management component with integrated coolant channels. This multi-functionality prevents thermal propagation while avoiding the need for separate cooling structures, thus resolving the contradiction between reliability improvement and device complexity increase.
Solution Approach 2:
The cooler beam acts as an intermediary thermal barrier between adjacent battery cells. By positioning the cooler beam between cells and integrating coolant channels within it, the system creates a thermal isolation zone that prevents heat transfer during thermal runaway, thereby improving thermal safety without requiring direct cell-to-cell cooling contact.
2Object-affected harmful factors
If cooler beams with integrated coolant channels are installed between battery cells, then thermal propagation is prevented, but the device complexity increases
Solution Approach 1:
The patent merges the structural support function and thermal management function into a single integrated cooler beam component. The coolant channels are embedded within the beam structure itself, combining what would traditionally be separate elements (support structure + cooling channels) into one unified component, thereby reducing overall system complexity while maintaining thermal protection.
Solution Approach 2:
The cooler beam is designed to perform multiple functions simultaneously: mechanical support for the battery pack and active thermal management through integrated coolant flow. This multi-functionality eliminates the need for additional separate cooling structures, preventing thermal propagation while avoiding excessive device complexity.
3Reliability
If active cooling measures are activated during thermal events, then thermal propagation is slowed down, but the response time for detection and activation is required
Solution Approach 1:
The cooler beams with coolant channels are pre-installed and positioned between all battery cells before thermal runaway occurs. The thermal management system is in place and ready for immediate activation, eliminating any delay in the physical cooling mechanism's deployment. Only the coolant flow activation requires time, which is minimized through direct integration.
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 solution effectively prevents or significantly slows down thermal propagation across cells, enhancing safety by reducing the risk of fires and maintaining the integrity of the battery system during thermal runaway events.
Implementation Method 1
Each of the cooler beams has a main channel integrated in the cooler beam and thermally connected to the cooler beam
Implementation Method 2
a channel system including a plurality of main channels, each of the main channels being configured to guide a coolant
Data Source
AI summary
A battery system includes a plurality of cell rows, each including a plurality of cells arranged along a first direction; a plurality of cooler beams; and a channel system including a plurality of main channels, each being configured to guide a coolant. Each of the cell rows is sub-divided into a plurality of blocks, and in each block, the front side positively abuts the second side of one cooler beam and/or the rear side positively abuts the first side of another cooler beam. For each of the cooler beams, one of the main channels is integrated therein and is thermally connected thereto.