Thermal-Sprayed Protective Element for Battery Thermal Runaway

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Solution Overview

Problem

Energy storage cells in electrically driven motor vehicles are vulnerable to thermal runaway during serious accidents, leading to the release of hot fluids that can damage surrounding materials and penetrate walls, posing a risk of consequential damage.

Innovation Solution

A protective element comprising a shielding element with a surface structure and a protective material, such as a high-temperature-stable alloy, is applied using thermal spraying to enhance the resistance to hot fluids, media, corrosion, and impact, thereby preventing damage from thermal runaway.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a protective element with protective material is applied to the shielding element, then the resistance to hot fluids and thermal runaway damage is improved, but the manufacturing complexity and production cost increase

Engineering Contradiction:

Improveprotection against thermal runawayVSAvoidstructure of protective element

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective element combines a shielding element (base material) with a protective material layer (coating) to create a composite structure. The shielding element provides mechanical strength and structural integrity, while the protective material layer provides thermal resistance and protection against hot fluids. This composite approach resolves the contradiction by achieving high reliability through material combination rather than using a single complex material system.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The protective material is applied in advance to the shielding element surface before the energy storage system operates. This preliminary protective coating prevents damage from thermal runaway events before they occur, eliminating the need for complex active protection systems that would require sensors, actuators, and control mechanisms during operation.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the protective material is applied using thermal spraying, then the protection against hot fluids and corrosion is improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improveresistance to hot fluidsVSAvoidapplication process of protective material

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical coating methods (such as brush painting or roller application) with thermal spraying technology. Thermal spraying uses thermal energy to melt and deposit protective material particles onto the shielding element surface, creating a dense, adherent coating with superior resistance to hot fluids and corrosion. This substitution resolves the contradiction by achieving high reliability through advanced manufacturing technology that, while requiring specialized equipment, provides superior performance and can be automated.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Stability of the object's composition

If the shielding element is designed with surface structures, then the resistance to thermally induced deformation is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveresistance to thermal deformationVSAvoidsurface structure geometry

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The surface structures (such as ribs, fins, or patterned features) on the shielding element are designed to accommodate and manage thermal expansion and deformation. These structures provide pathways for thermal stress relief and maintain structural integrity during thermal runaway events. The design resolves the contradiction by using purposeful geometric features that leverage thermal expansion principles rather than requiring extremely tight manufacturing tolerances on flat surfaces.

Inventive Principle:

Principle #37Thermal expansion

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 protective element effectively counters damage from external forces and accidents, reducing the risk of thermal runaway and allowing for increased energy density and vehicle range by protecting the energy storage system.

Implementation Method 1

the protective material can be arranged or formed on the surface by thermal spraying

Methodology Applied

Scientific EffectThermal spraying: Plasma Spray

Implementation Method 2

the protective material can in particular be used to increase the hot-fluid resistance of the shielding element

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20260027914A1Protective element, method for production thereof, energy storage system and motor vehicle

Publication Date: 2026.01.29 ELRINGKLINGER AG

AI summary

A protective element, in particular for an energy storage system or for a motor vehicle, wherein the protective element has the following: a shielding element, for example a wall, and a protective material arranged or formed on a surface of the shielding element.