Flash Cooling System for Battery Thermal Runaway Prevention
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Solution Overview
Problem
High energy density batteries in vehicles are prone to uncontrollable thermal runaway and explosions when subjected to mechanical stress, with little to no safety mechanisms in place to prevent the propagation of such reactions to adjacent batteries.
Innovation Solution
A flash-cooling system integrated with thermal and mechanical stress sensors that rapidly cool affected batteries using a coolant canister and delivery system, activated by a battery management system upon detection of abnormal conditions, to reduce the likelihood of thermal runaway and prevent its propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high energy density batteries are used in close proximity for vehicular applications, then energy storage capacity is improved, but the risk of thermal runaway propagation to adjacent batteries increases
Solution Approach 1:
The battery system is divided into multiple modular battery packs, each equipped with its own thermal management system. This segmentation isolates thermal runaway events to individual modules, preventing propagation to adjacent batteries while maintaining high energy density through close proximity arrangement of modular units.
Solution Approach 2:
Thermal barriers and cooling channels are introduced as intermediary elements between adjacent high-energy-density batteries. These intermediaries absorb and dissipate thermal energy, acting as a buffer that prevents direct thermal coupling between battery cells while allowing dense packing for maximum energy storage.
2Reliability
If cooling systems are added to battery packs for thermal management, then thermal runaway risk is reduced, but device complexity increases
Solution Approach 1:
The cooling system is merged with the existing battery pack structure, utilizing the same housing and mounting mechanisms. The thermal management channels are integrated into the battery cell design itself, combining structural support and thermal dissipation functions into a single unified system, thereby reducing overall complexity.
Solution Approach 2:
The cooling system is designed to serve multiple functions: it provides thermal management during normal operation, activates for thermal runaway prevention, and structurally supports the battery cells. This multi-functionality reduces the need for separate dedicated components, simplifying the overall system while maintaining high reliability.
3Speed
If rapid cooling is applied to affected batteries upon detection of abnormal conditions, then thermal runaway rate is reduced, but energy consumption increases
Solution Approach 1:
The rapid cooling system operates periodically rather than continuously, activating only when thermal sensors detect abnormal conditions approaching thermal runaway thresholds. This on-demand operation achieves rapid cooling response when needed while minimizing energy consumption during normal battery operation.
Solution Approach 2:
The cooling system adjusts its operational parameters dynamically based on thermal conditions. During normal operation, cooling is minimal or off; when thermal runaway risk is detected, the system transitions to high-intensity rapid cooling mode, optimizing the balance between cooling speed and energy consumption by matching power input to actual thermal threat levels.
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 system significantly reduces the rate and likelihood of thermal runaway reactions, minimizing the risk of explosions and fires by cooling batteries before mechanical damage can trigger a chain reaction, thereby ensuring safer battery operation and reducing damage in vehicular applications.
Implementation Method 1
a coolant canister and delivery system, activated by a battery management system upon detection of abnormal conditions, to reduce the likelihood of thermal runaway
Implementation Method 2
A flash-cooling system integrated with thermal and mechanical stress sensors that rapidly cool affected batteries using a coolant canister
Data Source
AI summary
In a battery pack having multiple battery cells distributed, for example, between multiple interconnected battery modules, a run-time cooling system is provided to cool (and/or heat) the battery cells during routine charging and discharging of the cells (e.g., powering a load such as a motor within an electric or hybrid-electric vehicle), and an emergency cooling system to cool the battery cells in response to a signal indicating detection of one or more conditions indicating possible thermal runaway within the battery cells or battery modules. The run-time cooling system, which may include a fan, HVAC unit or other fluid pumping device, induces continuous coolant flow within the battery pack (e.g., flow of air or other gaseous or liquid coolant). The emergency cooling system, by contrast, includes a mechanical interface or is otherwise adapted to receive a receptacle containing pressurized coolant or other flash-cooling device.