Modular Battery Cell Blocks for Thermal Runaway Containment
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Solution Overview
Problem
Existing multi-cell rechargeable energy storage systems (RESS) face challenges in efficiently managing thermal dynamics and structural rigidity, particularly in large-scale applications such as electric vehicles, where space optimization and thermal management are critical.
Innovation Solution
The modular RESS design incorporates interlocking battery cell blocks with thermal mitigation barriers, thermal insulators, and bus bar segments, along with cold plate segments and quick-connect devices, to enhance thermal management and structural integrity while allowing for adaptive packaging within vehicle body structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are organized into large-scale arrays to meet design objectives of charging rates and capacity, then energy storage capacity increases, but thermal management complexity and difficulty increase
Solution Approach 1:
The patent divides the battery array into modular battery cell blocks, each containing a limited number of battery cells (e.g., 4-9 cells per block). This segmentation allows thermal management to be handled at the block level rather than system-wide, reducing complexity. Each block can be independently thermally managed with its own cold plate segments and thermal mitigation barriers, preventing thermal runaway propagation while maintaining high overall capacity.
Solution Approach 2:
The patent introduces thermal mitigation barriers as intermediary components between adjacent battery cell blocks. These barriers act as thermal isolators that prevent heat transfer and thermal runaway propagation between blocks. The barriers include thermal insulator material and optionally phase change material, creating a thermal buffer zone that manages heat at block interfaces without requiring complex system-wide thermal management.
2Reliability
If battery cell blocks are designed with comprehensive thermal management components, then thermal runaway protection improves, but device complexity increases
Solution Approach 1:
The patent merges multiple thermal management functions into integrated components. The thermal mitigation barrier combines thermal insulator material with optional phase change material to simultaneously provide thermal isolation and heat absorption. The cold plate segments are integrated directly with battery cell block structures, combining cooling function with structural support. This merging reduces the number of separate components while maintaining comprehensive thermal protection.
Solution Approach 2:
The patent designs universal battery cell block modules that can be configured in various array arrangements to meet different capacity requirements. Each block is a self-contained unit with integrated thermal management components that can function independently or in combination with other blocks. The modular design allows the same block configuration to serve multiple purposes: energy storage, thermal management, and structural support, reducing overall system complexity.
3Strength
If modular battery cell blocks are used with interlocking structures, then structural rigidity improves, but manufacturing complexity increases
Solution Approach 1:
The patent segments the battery array into standardized modular blocks with consistent dimensions and interface configurations. Each block contains a fixed number of battery cells arranged in uniform patterns (e.g., 2x2, 3x3 configurations). This standardization simplifies manufacturing by allowing blocks to be produced independently using the same tooling and assembly processes, then combined into larger arrays without requiring custom manufacturing for each configuration.
Solution Approach 2:
The patent employs nested modular structures where standardized battery cell blocks are arranged in arrays to form battery modules, which are then combined to form the complete battery system. The interlocking structures and alignment features are designed to nest blocks together precisely, maintaining structural rigidity while allowing independent manufacturing of each block. This nesting approach enables complex overall structures to be built from simple, easily manufactured modular units.
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 modular design effectively manages thermal runaway events, maintains structural rigidity, and optimizes space usage within vehicle structures, thereby enhancing the charging capacity and operational range of electric vehicles.
Implementation Method 1
Each battery cell block includes a thermal insulator configured to line the cell vent
Implementation Method 2
Each battery cell block includes a thermal mitigation barrier (TMB) segment fixed to the cell case and configured to contact the adjacent battery cell block
Implementation Method 3
Each battery cell block may additionally include a cold plate segment configured to interconnect with a cold plate segment of the adjacent battery cell block
Implementation Method 4
Each battery cell block may additionally include a thermal interface material (TIM) segment arranged between the cold plate segment and the cell case
Data Source
AI summary
A modular multi-cell rechargeable energy storage system (RESS) includes a RESS enclosure surrounded by an external environment and having an enclosure tray and an enclosure cover. The RESS also includes a plurality of battery cell blocks arranged in the RESS enclosure. Each battery cell block includes a cell case including a cell vent and at least one electrically insulated structural connector configured to link the cell case with an adjacent battery cell block. Each battery cell block also includes a thermal mitigation barrier (TMB) segment fixed to the cell case and configured to contact the adjacent battery cell block. Each battery cell block additionally includes a thermal insulator configured to line the cell vent. Furthermore, each battery cell block includes a bus bar segment configured to interconnect with a bus bar segment of the adjacent battery cell block.