Horizontal Battery Module Structure for Thermal Runaway Isolation
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Solution Overview
Problem
Conventional lithium-ion batteries are limited in size due to vertical placement, which restricts their installation and requires additional space for heat removal, posing safety risks due to thermal runaway.
Innovation Solution
A horizontally-arranged module with a thermal runaway protection structure, featuring a heat insulation layer, connecting shell, and fireproof layer, where battery units are stacked perpendicular to the module surface, and equipped with structural adhesives and pressure relief holes to prevent heat transfer and pressure buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If lithium-ion batteries are placed vertically and independently, then the battery size is limited and requires additional space for heat removal, but the installation flexibility is reduced and safety risks increase due to thermal runaway
Solution Approach 1:
The patent inverts the conventional vertical placement of battery cells to a horizontal arrangement. This inversion allows batteries to be stacked in layers within the same footprint space, increasing energy density while the connecting shell and fireproof layers provide thermal isolation to prevent runaway propagation, thus improving both space utilization and safety
Solution Approach 2:
The patent implements a nested structure where multiple battery cells are stacked in layers within a connecting shell. The fireproof layers and heat insulation layers are nested between battery layers, creating a compact multi-layer configuration that maximizes space utilization while maintaining safety barriers against thermal runaway
2Area of stationary object
If conventional vertical battery placement is used, then heat removal requires additional space for exhaust channels, but horizontal stacking enables better space utilization and integrated thermal management
Solution Approach 1:
The patent merges the thermal management function into the structural design by integrating liquid cooling channels into the connecting shell that contacts multiple battery layers. This combines structural support and heat dissipation functions, eliminating the need for separate exhaust channels and improving space utilization while effectively managing temperature
Solution Approach 2:
The connecting shell serves multiple functions: it provides structural support for stacking batteries, acts as a thermal barrier with fireproof layers, facilitates heat removal through integrated cooling channels, and enables mechanical connection between battery layers. This multi-functionality reduces the need for additional components and optimizes space
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
Ensures high thermal diffusion safety, reduced module height, and effective heat management through dual-layer cooling, preventing thermal runaway propagation and maintaining structural integrity.
Implementation Method 1
the heat insulation layer is filled in a space between two adjacent battery units and a space between the two adjacent battery units and the connecting shells
Implementation Method 2
the fireproof layer is arranged between the battery units connected in series
Implementation Method 3
the liquid cooling plate is arranged between the cell modules, and the liquid cooling plate is welded with the connecting shell
Data Source
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AI summary
Provided is a cell horizontally-arranged module having a thermal runaway protection structure. The cell horizontally-arranged module comprises a cell module, an insulation protection member, an end plate, a connecting shell and a cooling member, wherein the cell module comprises a battery unit and a fireproof heat insulation layer; the battery unit and the fireproof heat insulation layer are alternately stacked, and the battery units are stacked in a thickness direction, such that the cell module is horizontally placed; the fireproof heat insulation layer prevents heat from being transferred to an adjacent battery unit via a side surface after the battery unit is in thermal runaway; output electrode plates are provided at two ends of the cell module; the insulation protection members are arranged on the output electrode plates, and the end plates are arranged outside the insulation protection members; the insulation protection members prevent the output electrode plates from coming into contact with the end plates after the cell module is in thermal runaway; and the connecting shell is arranged on a side face of the horizontally-arranged cell module, the connecting shell is connected to the end plates, and the cooling member is arranged on the connecting shell. The height of a chassis of a new energy vehicle is limited, the number of stacked layers of the horizontally-arranged module is relatively small, and the thermal diffusion safety level is high.