Sub-Modular Battery Pack Venting and Thermal Balancing
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Solution Overview
Problem
Existing battery packs in electric vehicles face challenges such as limited energy density, uneven temperature distribution leading to capacity fade and impedance growth, and potential thermal runaway events causing venting issues and safety hazards, with inefficient use of packaging space and varying vehicle wheelbases.
Innovation Solution
A modular and scalable battery pack design featuring multi-layer battery stacks with thermal management devices, compressive frames, and vent isolation mechanisms, along with centralized or distributed heating and cooling systems, and integrated sensors for thermal runaway detection and mitigation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multi-layer battery stacks are implemented to increase energy density, then energy density is improved, but thermal management complexity increases
Solution Approach 1:
The battery pack is divided into multiple independent modules, each with its own thermal management capabilities. This segmentation allows complex thermal management to be broken down into manageable units that can be independently controlled and maintained.
Solution Approach 2:
Multiple battery modules are stacked vertically to form a multi-layer configuration, with thermal management components integrated within and between layers. This nesting approach maximizes space utilization while maintaining manageable thermal control at each level.
2Volume of moving object
If battery cells are arranged in compact configurations to optimize space utilization, then space utilization is improved, but temperature distribution uniformity deteriorates
Solution Approach 1:
Thermal management components are strategically positioned at specific locations within the battery pack to address local heating patterns. Different regions receive targeted cooling or heating based on their specific thermal requirements, ensuring uniform temperature distribution despite compact arrangement.
Solution Approach 2:
The battery cells are arranged in a vertical multi-layer stack configuration rather than a single flat layer. This three-dimensional arrangement, combined with thermal management at multiple levels, improves space utilization while maintaining temperature uniformity through vertical heat dissipation paths.
3Reliability
If venting capacity is increased to handle thermal runaway events, then safety is improved, but device complexity increases
Solution Approach 1:
The venting system is segmented into multiple distributed vents located throughout the battery pack rather than a single centralized vent. This segmentation provides redundant safety pathways while keeping individual vent components simple and manageable.
Solution Approach 2:
The battery pack enclosure and venting system are designed to automatically respond to thermal runaway conditions without requiring external intervention. Pressure-sensitive vents automatically open when threshold pressures are reached, and the modular design allows automatic isolation of affected modules.
4Adaptability or versatility
If modular battery pack design is implemented to improve adaptability, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The battery pack is designed as a collection of standardized modular units that can be independently manufactured and then assembled in various configurations. This segmentation enables specialized manufacturing of individual modules while simplifying the overall assembly process through standardization.
Solution Approach 2:
The modular battery components are designed with universal interfaces and standardized dimensions that allow the same modules to be used across different vehicle types and applications. This universality reduces the number of unique parts that need to be manufactured while maintaining high adaptability.
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
Enhances energy density, balances temperature distribution, reduces maintenance downtime, and improves safety by effectively managing thermal events, while optimizing space utilization and weight distribution for various vehicle configurations.
Implementation Method 1
a thermal management device, such as an active heat exchanger or battery cold plate, that provides cooling or heating of the array of battery cells
Implementation Method 2
The heat exchanger includes a plurality of internal passages through which a heat transfer medium is actively circulated during operation
Implementation Method 3
The battery pack frame may also apply a compressive force to the multi-layer battery stack generally to hold the battery cells in place
Data Source
AI summary
A battery pack includes battery cells arranged in an array to form a battery module layer. Multiple layers are vertically stacked with thermal management devices, such as active heat exchangers in the form of battery cold plates, above and below each layer to form a multi-layer battery stack that may be held in compression by a battery pack frame. The multi-layer battery stack and battery pack frame are surrounded by a battery enclosure, which has flat sealing surfaces to ensure robust sealing. The battery pack is associated with a thermal management system for cooling and heating the battery cells of the battery pack. The battery thermal management system provides cooling and heating by alternating cooling flow directions to achieve uniform temperature distribution.