Battery Pack Cross-Member Venting With Thermal Control Flaps
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Solution Overview
Problem
Existing traction battery packs for electrified vehicles lack effective thermal management systems to control the flow of battery cell vent byproducts, which can lead to thermal events and compromise the structural integrity of the battery pack.
Innovation Solution
The integration of a cross-member assembly with a thermally insulating sheet and movable flaps that act as thermal control valves, allowing the flaps to move and control the flow of battery cell vent byproducts in response to temperature changes, thereby managing thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional rigid thermal management system is used, then structural strength is maintained, but thermal response speed is slow and cannot adapt to rapid temperature changes
Solution Approach 1:
The patent applies the dynamics principle by implementing flaps that can dynamically change position between open and closed states based on thermal conditions. These flaps are connected to the rigid ladder frame structure, allowing the system to combine structural strength with dynamic thermal response. The flaps move in response to temperature changes to control vent byproduct flow, achieving both structural integrity and adaptive thermal management.
2Reliability
If thermal management valves are integrated into the cross-member assembly, then thermal event control is improved, but device complexity increases
Solution Approach 1:
The patent applies the merging principle by integrating the thermal management valves (flaps) directly into the cross-member assembly structure. The flaps are attached to the ladder frame and work in conjunction with the vent openings, combining the structural support function with the thermal management function in a single integrated component rather than separate systems.
Solution Approach 2:
The patent applies the self-service principle by designing flaps that automatically open or close in response to thermal conditions without requiring external control systems. The flaps utilize the thermal environment itself to trigger their movement, enabling the system to self-regulate vent byproduct flow based on real-time temperature conditions.
3Reliability
If flaps are made movable to control vent flow, then thermal management effectiveness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies the flexible shells and thin films principle by using flaps that can be made from flexible materials allowing for controlled movement. These flaps are thin, movable components attached to the rigid ladder frame, enabling thermal response without requiring complex mechanical assemblies or high-precision manufacturing tolerances.
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 manages thermal events by controlling the flow of battery cell vent byproducts, reducing the risk of structural damage to the battery pack and ensuring safe operation of the vehicle.
Implementation Method 1
the pressure sensitive adhesive is configured to melt when a temperature of the battery cell vent byproduct exceeds a predefined temperature threshold to allow the flap to move to the second position
Implementation Method 2
a thermally insulating sheet for blocking the transfer of thermal energy from adjacent battery cell stacks within the traction battery pack
Data Source
AI summary
Battery cell stack cross-member assemblies are provided for traction battery packs. An exemplary cross-member assembly may include a thermally insulating sheet for blocking the transfer of thermal energy to adjacent structures inside the traction battery pack. The thermally insulating sheet incorporates thermal control valves in the form of movable flaps for controlling the flow of battery cell vent byproducts during battery thermal events.