Suspended Battery Pack Assembly for Thermal Venting and Impact Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Secondary batteries used in mobility applications face safety concerns due to thermal runaway events that can lead to fires and passenger compartment risks, as well as damage from impacts, as they are not adequately protected by existing designs.
Innovation Solution
A battery pack design featuring a housing with a top plate and bottom plate configuration, where the battery assembly is suspended and supported by the top plate with a thermal interface material, and a free volume between the battery assembly and bottom plate to vent gases and flames away from the passenger compartment, and absorb impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the battery assembly is closely supported on the base plate, then the structural stability is improved, but the safety is worsened due to impact damage risk and thermal runaway transmission
Solution Approach 1:
The support structure is segmented into multiple independent support portions distributed across the base plate, rather than a single continuous support. This segmentation allows the battery assembly to be supported while maintaining gaps between support points, enabling thermal runaway gas venting and impact absorption without compromising overall structural stability.
Solution Approach 2:
The design transitions from two-dimensional close support contact to three-dimensional spaced support with vertical clearance. The battery assembly is supported at discrete points while maintaining a gap above the base plate, creating a third dimension for thermal gas escape and impact cushioning, thus resolving the contradiction between stability and safety.
2Ease of manufacture
If the battery assembly is closely supported on the base plate, then the manufacturing simplicity is improved, but the safety is worsened due to thermal runaway gas concentration on the top plate
Solution Approach 1:
The continuous support structure is segmented into discrete support portions, simplifying the manufacturing process compared to creating complex continuous support structures with integrated venting channels, while simultaneously enabling safety functions through the created gaps.
Solution Approach 2:
The harmful function of close support (trapping thermal gases) is extracted by removing the continuous contact between the battery assembly and base plate, leaving only discrete support portions that maintain structural integrity while allowing thermal gas venting.
3Device complexity
If the battery assembly is closely supported on the base plate, then the device complexity is reduced, but the safety is worsened due to impact damage from below the vehicle
Solution Approach 1:
The support structure is divided into multiple simple discrete support portions rather than a complex continuous structure, reducing manufacturing complexity while enabling the safety function of impact absorption through the gaps between support points.
Solution Approach 2:
The design incorporates predetermined gaps between the battery assembly and base plate before impact occurs, providing cushioning space that absorbs impact energy from below the vehicle, preventing direct transmission of impact forces to the battery cells.
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 passenger safety by directing high-temperature gases and flames away from the passenger compartment and protecting the battery assembly from impacts, thereby improving the overall safety and durability of the battery pack.
Implementation Method 1
a first layer between the battery assembly and the first cover. The first cover may include a cooling channel
Implementation Method 2
The first cover may include a cooling channel between the first side of the first cover and a second side of the first cover
Implementation Method 3
a free volume between the battery assembly and bottom plate to vent gases and flames away from the passenger compartment
Data Source
AI summary
A battery pack including a housing, a battery assembly, and a first cover. The housing includes an opening and a first surface opposite the opening. The battery assembly is accommodated in the housing. The first cover is coupled to the housing and covers the opening. The first side of the battery assembly is coupled to a first side of the first cover. A second side of the battery assembly is spaced apart from the first surface of the housing.