Orthogonal Battery Cell Group Stacking for Thermal Runaway Prevention
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Solution Overview
Problem
Conventional battery module designs face safety issues due to thermal runaway propagation, where high energy density and packing density lead to increased risks of thermal runaway, and compartmentalization is costly and space-intensive.
Innovation Solution
The design alternates stacking of first and second battery cell groups with prismatic cells, where each group is oriented orthogonally to the other, enhancing thermal conductance and preventing thermal runaway expansion by distributing heat effectively between groups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are arranged in high-density packing to increase energy content, then energy density is improved, but thermal safety deteriorates due to increased risk of thermal runaway propagation
Solution Approach 1:
The battery module is segmented into multiple battery cell groups (first and second groups) that are alternately stacked. Each group acts as an independent thermal management unit, preventing thermal runaway propagation across the entire module while maintaining high cell density within each group.
Solution Approach 2:
Adjacent battery cell groups are oriented orthogonally to each other, creating local structural differentiation. This orthogonal arrangement at the group level provides thermal isolation pathways without compromising the overall high-density packing of individual cells within each group.
2Object-affected harmful factors
If compartmentalization structures are added to prevent thermal runaway propagation, then thermal safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The orthogonal stacking arrangement of battery cell groups serves multiple functions simultaneously: it provides thermal isolation to prevent runaway propagation, maintains high energy density, and creates a regular repeating pattern that simplifies manufacturing and assembly processes compared to complex partition structures.
Solution Approach 2:
Instead of adding compartmentalization structures between cells to prevent thermal propagation, the patent inverts the approach by orienting entire groups of cells orthogonally to each other. This group-level orientation naturally creates thermal isolation without requiring additional partition structures.
3Temperature
If orthogonal stacking of battery cell groups is implemented, then thermal conductance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The orthogonal stacking creates a periodic alternating pattern of first and second battery cell groups throughout the module. This regular periodic structure simplifies manufacturing by establishing repeating units with standardized orientation requirements, reducing the cumulative impact of precision variations.
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 arrangement improves thermal safety by effectively distributing heat and preventing thermal runaway propagation, while being cost-effective and space-efficient, thus enhancing the safety and performance of battery modules in electric vehicles.
Implementation Method 1
enhancing thermal conductance and preventing thermal runaway expansion by distributing heat effectively between groups
Data Source
AI summary
A battery module includes a plurality of first battery cell groups and a plurality of second battery cell groups. Each of the first battery cell groups and each of the second battery cell groups includes a plurality of stacked prismatic battery cells. At least one of the first battery cell groups is arranged adjacent to at least one of the second battery cell groups, the first battery cell groups and second battery cell groups are alternatingly stacked, and the battery cells of the first battery cell groups are oriented orthogonally to the battery cells of the second battery cell groups.