Traction Battery Hollow-Profile Chambers for Fire Isolation Venting

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Solution Overview

Problem

Traction batteries in electric vehicles face challenges in preventing the propagation of fires between adjacent cell stacks, as gas generated during thermal events can ignite adjacent cells, and existing solutions do not adequately ensure fire safety and efficient gas discharge.

Innovation Solution

The battery modules are configured as hollow profiles with chambers separated by intermediate walls, sealed with a lid and a separate sealing component, and equipped with degassing openings to prevent fire propagation and efficiently discharge gases, using elastomeric materials for enhanced sealing and temperature resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fire-resistant materials or partitions are provided between individual compartments with cell stacks, then fire propagation is prevented, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvefire safetyVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The battery module housing is divided into multiple fire-resistant compartments separated by intermediate walls. Each compartment contains cell stacks and is equipped with its own lid and sealing component, creating isolated chambers that prevent fire propagation between adjacent cell stacks while maintaining overall module integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Fire-resistant intermediate walls serve as intermediary structures between adjacent compartments. These walls act as barriers that block the path of hot gas and flames, preventing fire propagation from one compartment to another while allowing the battery module to maintain its structural integrity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If separate sealing components are used for intermediate walls, then sealing reliability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvesealing reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sealing system is segmented into multiple independent sealing components, each assigned to specific locations (intermediate walls and lids). This segmentation allows each sealing component to be optimized for its specific function and installed independently, improving overall sealing reliability while enabling modular manufacturing and assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Sealing components are pre-installed on intermediate walls and lids before final assembly of the battery module. This preliminary action ensures that sealing surfaces are properly prepared and sealed in advance, preventing leakage paths from forming during subsequent assembly operations

Inventive Principle:

Principle #10Preliminary action

3Reliability

If chambers are completely sealed to prevent fire propagation, then fire safety is improved, but gas discharge capability deteriorates

Engineering Contradiction:

Improvefire safetyVSAvoidgas accumulation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

Degassing openings are extracted from the sealed chamber structure and integrated into the lid. These openings provide dedicated pathways for hot gas to escape from each compartment during thermal events, preventing gas accumulation and pressure buildup while maintaining the fire-resistant separation between compartments

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The lid serves as an intermediary structure that combines multiple functions: it seals the compartment to prevent fire propagation, while simultaneously incorporating degassing openings that allow controlled gas discharge. This intermediary element reconciles the conflicting requirements of sealing and venting

Inventive Principle:

Principle #24Intermediary (Mediator)

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 configuration effectively prevents fire propagation between cell stacks, enhances vehicle safety by ensuring secure separation and gas-tight sealing, and allows for easy accessibility and maintenance of the battery modules.

Implementation Method 1

The end sections of the intermediate walls reaching to the opening cross-section are sealed with a separate sealing component against an inside of the lid

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

The battery modules protect the battery cells or cell stacks not only against mechanical stresses, especially in case of an accident

Methodology Applied

Scientific EffectMechanical protection:

Data Source

PatentUS20230411776A1Traction battery for a vehicle

Publication Date: 2023.12.21 DR ING H C F PORSCHE AG

AI summary

A traction battery of an electrically or semi-electrically driven vehicle includes one or more cooperating battery modules, in which a respective plurality of chambers are provided for receiving one or more cell stacks from a respective plurality of battery cells. The battery module is configured as a hollow profile, which includes the respective plurality of chambers separated from one another by intermediate walls and running parallel in a longitudinal direction of the hollow profile, into which chambers the cell stacks can be inserted. The hollow profile is sealed at both ends with a respective lid spanning end-side opening cross-sections of all chambers. End sections of the intermediate walls reaching to the opening cross-section are sealed with a separate sealing component against an inside of the lid.