Battery Thermal Runaway Prevention

Assembly for thermal management of individual cells in a battery pack that allows precise temperature control of each cell. The assembly has multiple features to address temperature regulation needs: 1. Thermal insulation between cells to prevent heat transfer. 2. Fluid passages for cooling or heating the cells. 3. Valves and flow control to selectively circulate fluids. 4. Temperature sensors and actuators to respond to cell conditions. 5. Fluid supplies for different operating conditions. The assembly enables independent temperature regulation of each cell without mixing fluids between cells. This prevents overheating or cooling of cells while avoiding thermal runaway. The fluid flow control allows customization based on factors like discharge level, charging rate, and ambient temperature.

Source

Battery thermal management system that optimizes heat dissipation for battery packs in electric vehicles without active cooling. The system uses sensors to monitor battery temperature and environmental conditions. It then calculates an optimal heat dissipation strategy based on factors like battery usage, ambient temperature, and airflow. This involves adjusting factors like fan speed, vent openings, and coolant circulation to efficiently dissipate heat without wasting energy on unnecessary cooling. The system can also predict future heat generation and proactively prepare the cooling system accordingly.

Source

Adaptive battery management for extending the life of high-voltage battery packs in electric vehicles by automatically adjusting charging and discharging limits based on cell condition data. The method involves measuring cell voltage, current, and temperature, processing the data through calibrated relationships to determine cell degradation values, and then modifying charge/discharge limits and thermal limits based on those values. This allows operating the battery at lower limits when cells are degrading to delay failure and extend overall pack life.

Source

Method for controlling battery temperature to optimize performance, extend battery life, and ensure safety by intelligently managing the battery's cooling and heating needs. The method involves monitoring battery temperature and dynamically adjusting the heat exchange power of an integrated cooling/heating system based on temperature thresholds. When the battery is too hot, the system cools with progressively higher power levels until temperature stabilizes. If the battery gets too cold, the system heats with increasing power until it warms up. This adaptive temperature control keeps the battery within an optimal range without overcooling or overheating.

Source

Battery temperature management system for electric vehicles with multiple battery packs arranged in series to reduce temperature variations between packs. The system uses adjustable heat transfer mechanisms between each pack and the cooling medium to balance temperatures. It makes the heat transfer capacity between packs further upstream smaller than packs further downstream. This prevents the downstream packs from overheating as the cooling medium warms up by sequentially exchanging heat with the packs. The system also maximizes heat transfer for the last pack to ensure it warms up. Temperature sensors monitor packs and adjustments are made based on detected temperatures.

Source

A system to prevent battery damage during charging by measuring battery temperature and controlling charge/discharge power. The system includes a temperature sensor in the battery to monitor temperature during charging. A battery management system (BMS) receives the temperature data and adjusts the charge/discharge power to prevent overheating and damage. This allows proactive cooling and protection of the battery during charging based on real-time temperature feedback.

Source

A vehicle battery system that can prevent damage from overcharging and cell failures. The system has an overcharge limit device that individually disconnects cells with high pressure. When a cell is disconnected, the controller stops controlling that cell and continues operating the rest. This prevents further overcharging. If multiple cells are disconnected, it stops all cells. This prevents overcharging of remaining cells. It also excludes disconnected cells from balancing and lowers the overall battery output limit.

Source

Electrified vehicle with a battery that can be power limited based on the thermal exchange capacity of the coolant fluid circulated by the thermal management system. The power limit is gradually reduced at higher battery temperatures to prevent sudden power interruptions. The limit lines increasing in steepness in correlation with thermal exchange capacity allow higher charge/discharge rates when the coolant temperature is lower. This balances battery performance and temperature management without unnecessary power limits.

Source

A retractable cord reel system for battery charging stations that prevents excessive heating of the charging cords and ensures safe operation. The system uses sensors to detect cord temperature and length. When the cord is partially retracted, it limits the charging current to prevent overheating. As more cord is unreeled, it increases the current. This prevents overheating due to trapped heat when fully coiled. The system also has venting and chimney effects to dissipate heat.

Source

Reducing battery swelling and degradation during charging by actively cooling the battery cell when it reaches full charge and high temperature. A thermoelectric cooler (TEC) is used to cool the battery cell when the state of charge (SOC) exceeds a threshold and the temperature exceeds a threshold. This prevents excessive heating and swelling during float or trickle charging, which can degrade battery life. The cooling is activated by the battery management system (BMS) controller based on SOC and temperature sensors.

Source

Fast charging of rechargeable batteries like lithium-ion cells without degradation or safety issues at low temperatures by preheating the battery internally using a heat spreader. The spreader is inserted partially or fully inside the battery cell and conducts heat from an external source to warm the cell before charging. This avoids the dangers of high current densities and lithium plating at cold temperatures. The spreader can contact the electrode terminals or be inside the cell housing. It enables rapid charging at temperatures like room temperature, which reduces time compared to waiting for internal heating during charging at low temperatures.

Source

A method for safely controlling the temperature of electric vehicle batteries to prevent overheating and thermal runaway without sacrificing performance. The method involves open-loop cooling of the battery instead of closed-loop regulation based on battery temperature. The cooling is independent of battery temperature and limits power consumption when certain thresholds are exceeded. This prevents temperature spikes from driving and charging. The open-loop cooling allows faster cooling than closed-loop regulation. If battery temperature exceeds high thresholds, it enters steps with progressively decreasing power limits. If temperature drops, it returns to normal operation. If battery temperature exceeds a higher threshold, both battery and cooling power limits are reduced. This prevents thermal runaway.

Source

Controlling cooling levels for battery modules in a battery pack to reduce temperature differences and improve uniformity of degradation between modules. The cooling is based on temperatures, states of charge, and states of health of multiple modules in the pack. A master management unit analyzes the temperature, charge, and health data from each module to determine an optimal cooling level for each fan. This allows coordinated cooling across the pack rather than just based on individual module temperatures.

Source

Balanced heat dissipation system for battery packs to prevent thermal runaway and improve battery life. The system uses heat pipes, superconducting materials, and active temperature management. Battery packs have heat pipes connecting cells to external heat sinks. Temperature sensors monitor cell and pack temps. A control unit analyzes voltage, current, resistance, environment to identify hot cells. It locks them, starts preset cooling programs, to avoid runaway. The heat pipes and external dissipation prevent temperature gradients and hot spots.

Source

Controlling thermal runaway propagation in battery packs with multiple modules by selectively discharging modules to prevent runaway spread. When a thermal runaway is detected in one module, the controller checks if current is flowing through that module. If not, it decouples the module to isolate the runaway. If current is flowing, it connects the other modules to an external load to discharge them, preventing runaway propagation. This controlled discharge can mitigate thermal runaway chain reactions in battery packs.

Source

Thermal protection system for electric vehicle charging that uses inline thermal switches to prevent overheating during charging. The thermal switches are placed in the electrical circuit between the charge source and receiver. They open above a threshold temperature to block transmission of the electrical signal. This stops the charging process when overheating is detected, mitigating safety hazards like fires and component damage. The inline placement ensures robust protection by stopping the charging operation when opened, versus out-of-line systems that may still allow charging with inactive signals.

Source

Battery cooling control to prevent temperature uniformity issues while minimizing battery degradation. The control involves regulating both heat dissipation and heat generation within the battery cell to maintain optimal cell temperature. When the internal cell temperature deviates from the external cell temperature, the control system adjusts dissipation and generation to bring the internal temperature back into range. This gentle cooling prevents rapid temperature swings that can degrade battery performance. By balancing internal and external temperature, it reduces temperature gradients and improves cell uniformity.

Source

Vehicle battery module with independent temperature control for each battery cell to prevent temperature variations between cells. The module has a heat transfer system with a heater, pipes, and a flow rate controller. A temperature sensor monitors each cell. The controller adjusts the heated fluid flow rate based on cell temperatures. It prioritizes heated fluid to low temperature cells. This prevents overheating or undercooling issues that can degrade battery performance or life.

Source

Battery thermal management system for electric vehicles that actively controls battery temperature during charging and discharging to improve charging efficiency and avoid thermal runaway. The system has a temperature acquisition subunit connected to the battery that continuously monitors battery temperature. A control subunit generates signals based on the battery temperature to a temperature control unit that adjusts heating or cooling of the battery. This maintains the battery within a stable temperature range during charging and discharging to prevent overheating and improve efficiency.

Source

Protecting electric vehicle charging connectors from excessive heat that can lead to connector failure and battery fires. The protection involves monitoring internal connector temperatures using thermostats. If temperatures exceed thresholds, steps like reducing voltage between pilot lines, switching off power, or activating alarms are taken to mitigate heating issues and avoid catastrophic connector failure.

Source