Expandable Effluent Containment Pouch for Thermal Runaway
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Solution Overview
Problem
Lithium-based electrochemical cells, such as lithium-ion and lithium-polymer cells, are prone to thermal runaway conditions, which can lead to unsafe failures and propagate to adjacent cells, posing risks to nearby equipment and electronics due to their high energy density and compact form factors, making it challenging to contain and prevent damage in applications like aerospace where weight and size are critical.
Innovation Solution
A compact, deployable containment system featuring a rigid housing with an expandable effluent containment pouch made from heat-tolerant materials, such as Nomex, Kevlar, and Mylar, that surrounds ports to capture effluent during thermal runaway events, directing it away from sensitive equipment and preventing further cell failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lithium-based cells are used to achieve high energy density and compact form factors, then specific power and specific energy are improved, but the risk of thermal runaway and damage to nearby equipment increases
Solution Approach 1:
The containment system divides the battery housing into separate compartments with effluent containment pouches positioned between individual cells. Each pouch is configured to contain effluent from a specific cell, preventing cross-contamination and thermal runaway propagation to adjacent cells while maintaining the high energy density benefits of lithium-based cells
Solution Approach 2:
The effluent containment pouches act as intermediary barriers between lithium-based cells and surrounding equipment. These pouches are positioned to intercept and contain thermal effluent before it can reach adjacent cells or external equipment, thereby mediating the harmful thermal effects while preserving the high specific energy characteristics of lithium-based cells
2Volume of moving object
If multiple cells are placed in close proximity within a small volume to achieve compact form factor, then cell density is improved, but thermal runaway propagation between cells increases
Solution Approach 1:
The housing is segmented into multiple compartments, each containing individual lithium-based cells with dedicated effluent containment pouches. This segmentation allows cells to be positioned in close proximity for compact form factor while the pouches create thermal barriers that prevent runaway propagation between adjacent cells
Solution Approach 2:
The effluent containment pouches are nested within the housing structure, positioned between adjacent cells. This nested configuration enables the pouches to occupy minimal space while effectively separating cells thermally, allowing high cell density without compromising reliability against thermal runaway propagation
3Object-affected harmful factors
If traditional containment structures are used to prevent thermal runaway damage, then safety is improved, but weight and size increase
Solution Approach 1:
The effluent containment pouches are constructed from flexible, thin-walled materials that can withstand thermal exposure. These thin-film pouches provide effective thermal containment and protection against runaway propagation while maintaining minimal weight and compact dimensions, unlike traditional rigid containment structures
Solution Approach 2:
The containment system transitions from a static rigid structure to a dynamic flexible pouch system that can expand and contract. The flexible pouches deform to accommodate thermal effluent volume changes during runaway events while maintaining containment integrity, providing effective protection with reduced weight compared to fixed rigid structures
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 solution effectively minimizes the risk of damage to nearby cells and equipment by containing thermal effluent efficiently, maintaining the compactness and light weight necessary for aerospace applications while preventing thermal runaway propagation.
Implementation Method 1
it can enter a thermal runaway condition in which it quickly combusts or suffers undesirable thermal expansion characteristics
Implementation Method 2
A compact, deployable containment system featuring a rigid housing with an expandable effluent containment pouch made from heat-tolerant materials, such as Nomex, Kevlar, and Mylar
Data Source
AI summary
A containment system (100) includes a housing (106). A battery pack (104) is situated within the housing. One or more ports (114) are disposed along a surface of the housing. An effluent containment pouch (108) is coupled to the surface of the housing. The effluent containment pouch spans the one or more ports. The effluent containment pouch expands when an electrochemical cell (105) experiences a thermal runaway condition, capturing expelled effluent (116).