Thermal Barrier Structure for Battery Pack Runaway Containment

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Solution Overview

Problem

Secondary batteries, particularly lithium-ion cells, are prone to thermal runaway due to unstable chemistries, leading to cascading thermal events in battery packs, causing damage and safety hazards.

Innovation Solution

Implementing thermal barrier elements with high melting temperatures and low thermal conductivity to divide battery packs into groups, preventing the propagation of thermal runaway events between cell groups, and integrating heat transfer channels coupled to passive or active cooling systems to manage thermal energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal barrier elements are added to divide battery packs into groups, then thermal runaway propagation is prevented, but device complexity increases

Engineering Contradiction:

Improvethermal runaway containmentVSAvoidbattery pack structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The battery pack is divided into multiple cell groups with thermal barrier elements positioned between adjacent groups. Each thermal barrier element is configured to prevent thermal runaway propagation from one cell group to another, effectively segmenting the battery pack into isolated thermal zones while maintaining overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Thermal barrier elements serve as intermediary components between adjacent cell groups. These barriers act as mediators that block thermal energy transfer during thermal runaway events, preventing direct thermal coupling between cell groups while allowing normal operation without interference.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If thermal barrier elements with high melting temperature and low thermal conductivity are used, then thermal insulation performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidthermal barrier element fabrication

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The thermal barrier elements are designed with specific material parameters including high melting temperature (greater than 1000°C) and low thermal conductivity (less than 20 W/mK at 25°C). These parameter specifications ensure adequate thermal insulation performance while providing clear manufacturing criteria for material selection and fabrication processes.

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

Minimizes battery pack damage and personnel hazards by containing thermal runaway events within isolated cell groups, reducing the risk of cascading thermal events and collateral damage.

Implementation Method 1

at least one thermal barrier element dividing the battery pack into a plurality of cell groups... The thermal barrier element(s) prevents a thermal runaway event in one group of cells from initiating a second thermal runaway event in an adjacent group of cells

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS8541126B2Thermal barrier structure for containing thermal runaway propagation within a battery pack

Publication Date: 2013.09.24 TESLA INC

AI summary

A battery pack is provided that includes one or more thermal barrier elements, the thermal barrier elements dividing the cells within the battery pack into groups of cells. The thermal barrier elements that separate the cells into groups prevent a thermal runaway event initiated in one group of cells from propagating to the cells within a neighboring group of cells.