Foam-Core Thermal Partitioning Between Battery Arrays
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Solution Overview
Problem
Thermal energy cascades from one battery array to another in a traction battery pack, posing a risk of thermal events and inefficiencies in energy distribution.
Innovation Solution
A thermal control assembly with a partitioning region featuring a foam core and a multilayer thermal blanket, including a glass-based mat layer and ceramic film coating, is positioned between battery arrays to block thermal energy transfer, with the partitioning region sewn to the thermal blanket and extending into the gap between arrays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery arrays are placed adjacent to each other in a traction battery pack, then space utilization and energy distribution efficiency are improved, but thermal energy can cascade from one array to another causing thermal events
Solution Approach 1:
The patent divides the battery pack into separate arrays with partitioning regions between them. These partitioning regions include foam cores and thermal control assemblies that segment the thermal pathways, preventing thermal energy from cascading between adjacent battery arrays while maintaining close proximity for efficient energy distribution.
Solution Approach 2:
The patent introduces thermal control assemblies and partitioning regions as intermediary elements between adjacent battery arrays. These intermediaries include foam cores and thermal blankets that act as thermal barriers, blocking harmful thermal energy transfer while allowing the arrays to remain adjacent for spatial efficiency.
2Reliability
If thermal control assemblies are added between battery arrays to block thermal energy, then thermal safety is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple functions into integrated components. The partitioning regions serve both as structural dividers and thermal barriers simultaneously. The thermal control assemblies are merged with the partitioning structure, eliminating the need for separate thermal management components and reducing overall assembly complexity.
Solution Approach 2:
The partitioning regions are designed to perform multiple functions: they provide structural separation between arrays, act as thermal barriers to block heat transfer, and maintain the adjacency of battery arrays for compact packaging. This multi-functionality reduces the number of separate components needed.
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
Effectively reduces thermal energy transfer between battery arrays, mitigating the risk of thermal cascades and maintaining electrical insulation, thus enhancing the thermal management of the battery pack.
Implementation Method 1
a partitioning region of the thermal control assembly, the partitioning region extending to a position between the first battery array and the second battery array, the partitioning region including a foam core
Implementation Method 2
a thermal control assembly that includes a thermal blanket spanning across the first battery array and the second battery array
Data Source
AI summary
A battery pack assembly includes a first battery array, a second battery array adjacent the first battery array, a thermal control assembly that includes a thermal blanket spanning across the first battery array and the second battery array, and a partitioning region of the thermal control assembly. The partitioning region extends to a position between the first battery array and the second battery array. The partitioning region includes a foam core.