Prismatic Battery Can Insert for Thermal Runaway Mitigation

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Solution Overview

Problem

Lithium-ion batteries in electric vehicles generate significant heat during charge and discharge cycles, leading to potential thermal runaway events that can spread to adjacent cells and affect nearby components, posing a safety risk.

Innovation Solution

A thermally conductive insert is incorporated into the battery cell design, dividing it into volumes that conduct heat to actively-cooled channels or a bottom cold plate, using materials like aluminum or copper alloys to manage thermal energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If battery cells are placed in close proximity to maximize energy density, then the quantity of battery cells per unit volume increases, but heat generation increases and thermal runaway can spread to adjacent cells

Engineering Contradiction:

Improvebattery cell densityVSAvoidthermal runaway propagation

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The battery can is divided into multiple compartments by thermally insulating partitions, creating separate chambers that physically isolate adjacent battery cells. This segmentation prevents thermal runaway in one cell from propagating to neighboring cells while maintaining high cell density within each compartment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Thermally insulating partitions act as intermediary barriers between adjacent battery cells. These partitions are specifically designed to impede heat transfer while allowing electrical connections to pass through, thereby preventing thermal runaway propagation without compromising electrical functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermally insulating partitions are added to prevent thermal runaway propagation, then safety improves, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvethermal runaway preventionVSAvoidbattery can structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The thermally insulating partitions are designed to serve multiple functions simultaneously: they provide thermal insulation to prevent runaway propagation, act as structural support elements within the battery can, and include integrated features for electrical connections and coolant flow. This multi-functionality reduces the need for separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The partition structure is merged with the cooling system by integrating coolant channels directly into the partitions. This combination eliminates the need for separate cooling components and simplifies the overall battery can structure while maintaining both thermal insulation and active cooling functions.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If thermally insulating partitions are added to prevent thermal runaway, then safety improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvethermal isolationVSAvoidpartition alignment

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The partitions are designed with uniform thickness and standardized geometric features throughout, allowing for consistent manufacturing using injection molding or extrusion processes. This homogeneity reduces variability and simplifies quality control compared to non-uniform partition designs.

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The partition design incorporates specific geometric parameters such as rounded corners, tapered edges, and standardized mounting features that are optimized for manufacturing. These parameter choices enable the use of conventional molding processes with standard tolerances, reducing the need for high-precision machining or assembly.

Inventive Principle:

Principle #35Parameter changes

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 insert effectively reduces peak temperatures during recharge cycles, mitigating the risk of thermal runaway and maintaining battery safety.

Implementation Method 1

The thermally conductive insert conducts heat from the center of the battery cell during battery recharging to actively-cooled channels disposed in a pair of cooling manifolds that are disposed on opposite vertical sides of the battery cell, and/or to an actively-cooled bottom cold plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12500284B2Prismatic battery can with a thermally conductive insert

Publication Date: 2025.12.16 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A mechanical design of a rechargeable battery cell (e.g., a Lithium-ion battery) disposed inside of a prismatic can, for use in electric vehicles and other electric-powered devices. The improved design uses a thermally conductive insert to divide the battery cell into two adjacent volumes that each hold a pair of stacked layers of a battery cell. This thermally conductive insert conducts heat from the center of the battery cell during battery recharging to actively-cooled channels disposed in a pair of cooling manifolds that are disposed on two vertical sides of the battery cell. Alternatively, or additionally, an actively-cooled bottom cold plate can be used. The pair of stacked battery layers can each be wound in a “jelly-roll” geometric configuration. The thermally conductive insert may be made of aluminum, aluminum alloy, copper, or copper alloy, and combinations thereof.