Pyrotechnic Battery Pack Isolation for Fault Containment
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Solution Overview
Problem
Existing battery management systems in electric vehicles lack effective and cost-efficient methods to isolate faulty battery packs, which can lead to further damage or failure propagation.
Innovation Solution
A battery management system (BMS) that includes supplementary fuses configured to blow and create an open circuit between battery packs upon detecting fault conditions, using pyrotechnic disconnect mechanisms to isolate faulty battery packs, thereby preventing further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery isolation methods are used, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs disposable pyrotechnic disconnect devices that are activated once to permanently isolate faulty battery packs. These single-use isolation mechanisms provide reliable circuit breaking without the complexity of reusable, controllable switches or relays, thereby resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The invention extracts the isolation function from complex electronic control systems and implements it through dedicated pyrotechnic disconnect devices integrated directly into the battery pack architecture. This extraction simplifies the overall system by providing a standalone, fail-safe isolation mechanism that operates independently of the BMS electronic control pathways.
2Device complexity
If pyrotechnic disconnect is used, then device complexity is reduced, but safety concerns may arise
Solution Approach 1:
The pyrotechnic disconnect device is segmented into isolated chambers containing the pyrotechnic composition, separated from other battery components by fire-resistant barriers. This segmentation confines any potential pyrotechnic reaction to a small, controlled volume, preventing propagation to adjacent battery cells or systems and mitigating safety risks while maintaining simplicity.
Solution Approach 2:
Fire-resistant barriers and thermal insulation materials serve as intermediaries between the pyrotechnic composition and surrounding battery components. These intermediary elements absorb and block thermal energy, creating a protective buffer that prevents harmful thermal effects from reaching sensitive battery areas while allowing the pyrotechnic mechanism to function.
3Reliability
If supplementary fuses are added to each battery pack, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The pyrotechnic disconnect device performs multiple functions: it acts as a circuit breaker, a safety device, and an isolation mechanism all in one component. This multi-functionality eliminates the need for separate fuses, relays, and control circuitry, thereby improving reliability while actually reducing manufacturing costs through component consolidation rather than addition.
Solution Approach 2:
The invention merges the isolation function with the existing battery pack terminal structure by integrating pyrotechnic disconnect devices directly into the electrical connection points. This consolidation combines multiple functions (connection, isolation, protection) into unified components, simplifying the manufacturing process and reducing overall system cost while enhancing reliability.
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 system effectively isolates faulty battery packs, preventing further damage and reducing the need for continuous power consumption, while offering a cost-effective alternative to traditional isolation methods.
Implementation Method 1
The supplementary fuse is configured to blow to electrically isolate the second battery pack from the first battery pack by initiating an open circuit between the second terminals
Data Source
AI summary
A battery system includes a plurality of battery packs and a battery management system (BMS). The BMS is operably coupled to the plurality of battery packs. The plurality of battery packs includes a first battery pack and a second battery pack. The first battery pack includes a first plurality of battery cells, a first fuse, and first terminals. The second battery pack includes a second plurality of battery cells, a second fuse, second terminals, and a supplementary fuse. The second terminals are electrically connected in parallel with the first terminals. The BMS is configured to monitor operational parameters of the plurality of battery packs; detect a fault condition in at least one of the plurality of battery packs; and initiate actuation of the supplementary fuse in response to the detected fault condition. The supplementary fuse is configured to blow to isolate the second battery pack from the first battery pack.