Thermal Barrier Sealing Between Battery Pack Cell Compartments
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Solution Overview
Problem
Current thermal barrier assemblies in traction battery packs fail to effectively prevent the transfer of thermal energy between cell stack compartments during thermal events, leading to inefficiencies in heat management and potential battery damage.
Innovation Solution
The implementation of a thermal barrier assembly with a tongue-and-groove connection and adhesive sealing between cross-member beams, heat exchanger plates, and other structural components to create sealed interfaces that inhibit thermal energy transfer, utilizing materials like stainless steel and aerogel for insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal barrier assemblies are used in traction battery packs, then heat management efficiency is improved, but thermal energy still transfers between cell stack compartments during thermal events
Solution Approach 1:
The patent employs seals comprising flexible materials (such as rubber or polymer seals) that create tight sealing interfaces between the thermal barrier assembly and adjacent structures. These flexible seals conform to the mating surfaces and prevent thermal energy transfer pathways, thereby eliminating the harmful thermal coupling between cell stack compartments while preserving the thermal barrier's heat management function.
Solution Approach 2:
The thermal barrier assembly utilizes composite construction combining thermally insulating materials (such as aerogel or ceramic composites) with structurally sound materials. This composite approach provides both the necessary thermal insulation properties to manage heat and the mechanical strength to maintain rigid sealing interfaces that block thermal energy transfer during thermal events.
2Strength
If rigid structural connections are used between thermal barrier assembly and cross-member beams, then structural integrity is improved, but thermal energy can cascade across the connection points
Solution Approach 1:
The patent introduces seals as intermediary elements positioned at the interfaces between the thermal barrier assembly and cross-member beams. These seals act as thermal break mediators that maintain the structural connection and rigidity while simultaneously blocking the direct thermal conduction pathway. The seal material serves as a thermal insulator that prevents heat cascading while allowing mechanical load transfer.
Solution Approach 2:
The connection system is segmented into distinct functional zones: rigid structural contact areas for load bearing and sealed interface areas for thermal blocking. The seals create discrete thermal barriers at each connection point, segmenting the thermal pathways while preserving structural continuity. This segmentation allows the structure to remain rigid while preventing thermal energy cascading through the connection points.
3Object-affected harmful factors
If sealed interfaces are created using adhesive alone, then thermal energy transfer is blocked, but the connection strength may be insufficient
Solution Approach 1:
The patent merges multiple connection mechanisms into a unified interface system: mechanical interlocking features (such as recesses and protrusions) provide rigid structural attachment, while seals (comprising flexible materials) are integrated into the same interface to provide thermal blocking. This combination of mechanical bonding and sealing ensures both strong structural connection and effective thermal energy transfer prevention, with each mechanism compensating for the limitations of the other.
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
This configuration effectively prevents thermal energy from cascading across cell stacks, enhancing heat management and structural integrity, thereby protecting battery cells during thermal events.
Implementation Method 1
an adhesive is disposed between the male portion and the female portion
Implementation Method 2
a thermal barrier assembly connected to the first cross-member beam by a tongue-and-groove connection
Implementation Method 3
utilizing materials like stainless steel and aerogel for insulation
Implementation Method 4
utilizing materials like stainless steel and aerogel for insulation
Data Source
AI summary
Thermal barrier assemblies are provided for use within traction battery packs. An exemplary thermal barrier assembly may include features for establishing a sealed interface relative to one or more adjacent structures of a traction battery pack. In some implementations, the thermal barrier assembly may provide features for interfacing with cell stack cross-members beams, upper enclosure structures, lower enclosure structures, etc. The sealed interfaces substantially prevent thermal energy from moving from compartment-to-compartment/cell packet-to-cell packet during a battery thermal event.