Lightweight Battery Enclosure With Vented Thermal Runaway Containment
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Solution Overview
Problem
Thermal runaway events in batteries, such as lithium-ion batteries, occur when temperature exceeds the normal operating range, leading to energy release and potential battery failure, which can impact vehicle operations. Current battery enclosures are heavy, reducing energy density and failing to effectively manage high temperatures.
Innovation Solution
The use of a lightweight nickel-chromium alloy enclosure with a venting system and cooling mechanisms, including external cooling plates and graphite heat spreaders, to manage temperature and prevent thermal runaway. The enclosure is designed to be durable and hermetically sealed, with a diaphragm and puncture pin system to release pressure during thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional battery enclosures are used, then structural strength is maintained, but weight increases reducing energy density
Solution Approach 1:
The patent employs composite material structures for the battery enclosure, combining lightweight materials with sufficient mechanical strength. The enclosure integrates multiple material layers including aluminum alloys and polymer composites that provide both weight reduction and structural integrity during thermal runaway events.
2Reliability
If heavier enclosure materials are used, then enclosure strength and containment capability are improved, but energy density decreases
Solution Approach 1:
The enclosure design implements local quality enhancement by concentrating reinforcement materials and thermal management components at critical locations where thermal runaway propagation is most likely to occur, rather than uniformly strengthening the entire enclosure structure.
Solution Approach 2:
The battery enclosure is segmented into multiple functional zones including isolated compartments for individual battery cells, dedicated thermal management sections, and structured venting pathways that compartmentalize thermal runaway events to prevent propagation across the entire battery pack.
3Temperature
If conventional cooling systems are added, then temperature management is improved, but device complexity increases
Solution Approach 1:
The cooling system is merged with the enclosure structure itself, where the enclosure walls double as thermal management conduits. Cooling channels are integrated directly into the enclosure geometry, eliminating separate cooling components and reducing overall system complexity.
Solution Approach 2:
The enclosure structure serves multiple functions simultaneously: structural containment, thermal management through integrated cooling channels, and directed venting of thermal runaway gases. This multi-functionality reduces the need for separate dedicated components for each function.
4Reliability
If pressure venting mechanisms are added, then safety during thermal runaway is improved, but enclosure integrity is compromised
Solution Approach 1:
Pressure venting mechanisms are pre-configured in the enclosure design with predetermined failure points that open at specific pressure thresholds. These mechanisms are designed in advance to release pressure at controlled locations, preventing uncontrolled enclosure failure while maintaining integrity during normal operation.
Solution Approach 2:
The venting system uses intermediary components such as rupture discs and pressure-relief valves that mediate between the internal pressure buildup and the external environment, allowing controlled pressure release while maintaining overall enclosure integrity and preventing catastrophic failure.
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 provides a high energy density battery assembly that effectively contains and manages thermal runaway events, reducing the risk of battery failure and improving vehicle performance by maintaining stable temperatures and preventing enclosure eruption.
Implementation Method 1
a cooling plate having a fluid channel between an inlet port and an outlet port. The cooling plate is to reduce a temperature of the battery
Implementation Method 2
including external cooling plates and graphite heat spreaders, to manage temperature
Implementation Method 3
when pressure increases in the cavity, the diaphragm flexes outward and is punctured by the puncture pin
Implementation Method 4
The load spreader is at least partially compressing the battery cell between the load spreader and the second end wall
Data Source
AI summary
Batteries, battery components, and related methods and apparatus for mitigating a thermal runaway event of a battery are disclosed. Examples disclosed herein include a battery including an enclosure defining a cavity, the enclosure including a first end wall and a second end wall opposite the first end wall, a battery cell disposed in the cavity of the enclosure, a load spreader disposed in the cavity of the enclosure, the load spreader spaced from the first end wall, the battery cell disposed between the load spreader and the second end wall of the enclosure, the load spreader at least partially compressing the battery cell between the load spreader and the second end wall.