EV Battery Packaging to Prevent Thermal Runaway

Testing materials used in battery packs to contain thermal runaway of individual cells. The testing involves exposing barrier materials between cells to actual or simulated conditions of a thermal runaway. The tests are done in enclosures with arrays of cells and sensors to measure characteristics during thermal runaway. This allows evaluating the containment ability of barrier materials in realistic battery pack conditions.

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Controlling battery thermal management in electric vehicles to prevent thermal runaway from spreading between battery modules. The method involves detecting battery cell temperature and voltage to identify the location of thermal runaway. Then, heating devices near the thermal barrier on the opposite side of the runaway cell are activated to generate heat. This minimizes thermal transfer to the barrier and prevents further spread. The technique allows reducing barrier thickness without risking runaway propagation.

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Managing thermal energy within a traction battery pack of an electrified vehicle to prevent cell venting debris from spreading to adjacent cells during thermal events. The technique involves securing thermal blockers between adjacent battery cells using an adhesive-backed base assembly that sandwiches between the cells. This prevents vent byproducts from migrating between cells during a thermal event. The base assembly can be an adhesive tape, securing the thermal blockers and adjacent cells together. The adhesive tape also provides mechanical support to the cells. The technique helps contain thermal runaway within cells and prevent cell-to-cell propagation.

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Mitigating thermal events in energy storage systems like lithium-ion batteries to prevent thermal propagation to adjacent cells after a portion of the battery has experienced a thermal runaway. The mitigation involves using a thickness of thermal barrier material in the battery cells, modules, or packs to prevent heat transfer and isolation of cells from each other. This allows higher cell densities and energy densities while reducing the risk of thermal runaway propagation.

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Battery module design to prevent flame propagation between cells and suppress heat transfer when one cell catches fire. The module has a stack of battery cells enclosed in insulating spaces separated by blocking members. The insulating spaces prevent direct flame spread and heat transfer between cells. A heat dissipation plate on one side allows external heat removal. This isolates cells and contains failures to prevent chain reactions.

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Reducing heat propagation between adjacent cylindrical battery cells in a battery pack to prevent thermal runaway from spreading. The solution involves inserting a thermal insulation material between the cells in the axial direction. The insulation has high reflectance in the 1000-10000 nm wavelength range to block heat radiation. It completely covers the cells, shielding them from each other's heat radiation. This helps prevent thermal runaway in one cell from spreading to the adjacent cell.

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Vehicle with battery compartment safety system that automatically opens the compartment covers when battery temperature reaches a critical level to prevent thermal runaway propagation. The system uses thermosensitive devices to detect high battery temperature and pneumatic actuators to instantly open the compartment covers. This allows rapid cooling to contain thermal runaway without needing manual intervention.

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Battery pack for electrified vehicles with vent gas passageways to mitigate thermal events and protect the enclosure while reducing debris discharge. The battery pack has a vent gas passageway within the enclosure that aligns with the cell vents. This passageway has inlet ports at each cell vent location. When a cell vent releases gas during a thermal event, it enters the corresponding inlet port and flows through the passageway instead of directly into the enclosure. This prevents gas discharge into the vehicle while mitigating pressure and temperature spikes. The passageway can also have features like serpentine channels or frangible sections to further reduce risks.

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Battery pack with a heat transfer member that allows rapid cooling of a specific battery cell in a pack with multiple cells in close contact to prevent thermal runaway from spreading. The heat transfer member has ports for introducing and discharging a cooling fluid. Valves in the ports open and close based on cell temperature. This allows reusing the heat transfer member by cyclically introducing and discharging fluid. It also provides a small amount of fluid residue and a vacuum to seal the member when closed. This enables targeted cooling of a failing cell to prevent thermal runaway propagation.

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Battery assembly and power supply apparatus with improved thermal management and safety features. The battery assembly has a distributed heat sink made of interconnects between the batteries. This allows equalizing battery temperatures and preventing hot spots. The heat sink is integrated into the battery pack design. The pack also has a thermal exchange device with surfaces for heat exchange and a contact surface in thermal contact with the interconnects. This allows transferring battery terminal heat to the heat sink. This aids cooling and prevents terminal overheating. The pack has battery management circuitry and a housing with a discharge chamber to contain thermal runaway. The housing has insulated upper walls to prevent air exchange and improve temperature sensing accuracy.

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Electric vehicle design with improved safety in case of battery thermal events. The vehicle has longitudinal sills on each side and a battery pack sandwiched between them. If the battery overheats, it has a degassing device to release gases. A duct is formed between the battery and one sill to guide the gases out. This prevents them from reaching occupants or other components. A heat-resistant deflection device between the battery and sill can also be added to further protect against hot gases.

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Battery module design to improve cooling uniformity and reduce temperature variation in electric vehicle battery packs. The module has heatsinks attached to both sides of the battery cell and a pair of perpendicular cooling plates contacting the bus bar. This direct contact cooling setup improves heat dissipation and reduces temperature gradients compared to conventional modules with heatsinks only on one side.

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Supporting housing for battery compartments of electric vehicles that uses flat metal sheets for cost-effective mass production, while integrating passive thermal management and other functions. The housing consists of deep-drawn shells that fit together to form a double-floor compartment. The batteries sit on the double-floor separated from the thermal management system. Coolant channels in the outer shell indirectly cool/heat the compartment. Sensors can be integrated into the double-floor for battery status monitoring. The double-floor design isolates the batteries from the cooling system to prevent short circuits. The thin metal sheets have high thermal conductivity for efficient heat transfer.

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Partition member for preventing thermal runaway propagation in assembled lithium-ion battery packs. The partition member separates individual battery cells in the pack. It has two surfaces in the thickness direction. If the average temperature of one surface exceeds 180°C, the thermal resistance per unit area (θ1) in that direction satisfies a specific expression. If both surfaces stay below 80°C, the thermal resistance per unit area (θ2) in both directions satisfies a different expression. This allows controlling heat transfer between cells based on temperature levels.

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Phase change composite battery thermal management system that integrates cooling, heating, and waste heat recovery to efficiently maintain optimal battery operating temperature. The system uses a phase changer, heat exchanger, electric heater, thermoelectric converter, and valve. Air is circulated through the system to cool the battery during normal operation. In low temperatures, waste heat from thermoelectric conversion is used to heat the battery. This prevents battery degradation and thermal runaway by maintaining optimal temperature.

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High-voltage battery for electric vehicles that prevents damage to the electronic components during thermal events in the battery cells. The battery has a housing with separate compartments for the battery cells and components. A barrier seals between the compartments to prevent exhaust gas from damaged cells flowing into the component compartment. This isolates the components from the hot gas and ensures their functionality when a cell overheats.

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A cooling system for battery packs that prevents thermal runaway propagation between cells. The system uses a cooling member between adjacent cells and a heat insulation member between the cooling member and cells. This inhibits heat spread from out-of-control cells to prevent further cells from thermal runaway. The cooling member is located between cells and the heat insulation member is between the cooling member and cells. This cooperative arrangement between the cooling member and heat insulation member prevents heat spread between cells.

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Energy storage system for electric vehicles with improved cooling, efficiency, and crash safety compared to conventional pack designs. The system uses parallel cooling across modules and battery cells to balance temperatures. Each module has two halves with cylindrical battery cells sandwiched between current carriers and plates. Coolant circulates in parallel through the modules and cells to maintain uniform temperatures. This avoids hotspots and reduces imbalance. The pack also has a tray with the modules and a central coolant system to circulate coolant across all modules in parallel. This prevents localized heating in modules and improves overall pack temperature regulation.

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Battery pack with improved thermal management for extended life and safety. The pack has multiple features to manage heat in each cell. It uses a detection mechanism to monitor cell temperatures. A temperature limiter switch controls cell operation based on the temperature readings. An equalizer device adjusts heat balance between cells. This allows fine-grained temperature control for each cell instead of just system cooling. It prevents hot spots and thermal runaway. The pack also has a cooling plate to remove excess heat.

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Battery design to mitigate thermal runaway and internal shorting during mechanical abuse. The technique involves adding materials and configuring components in the battery to increase impedance and prevent thermal runaway before it can occur. Damage initiators like passive particles, fibers, or coatings in electrodes deform and fracture during impact to cause widespread damage. Active additives like chemicals, foams, or elastic materials release, absorb, or displace during loading to increase impedance. Shape changes in separator or case promote bending, shear, or debonding in electrodes. By intentionally weakening and deforming parts, damage propagation is promoted to mitigate thermal runaway before it starts.

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