Thermal Runaway Barriers for EV Battery

Process for preparing geopolymer or geopolymer composite without curing, drying, and milling steps. The geopolymer formation is modified by adding water-soluble compounds like phosphoric acid or ammonium polyphosphate during steps f and g. This encapsulates additives like coke, anthracite, graphene oxide, metal oxides, sulfides, or magnesium compounds into the geopolymer matrix. The modified geopolymer or composite has enhanced self-extinguishing properties and reduced thermal conductivity compared to unmodified geopolymer.

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Battery pack assembly for electric vehicles that improves safety during cell thermal runaway. The pack has a frame with integrated channels for exhausting fumes. The channels are integrated into the frame instead of a separate tray. This allows fumes to escape when cells vent during thermal runaway, preventing them from spreading to other cells. It also isolates the fumes from the pack housing. The channels are parallel and vertically connected to the exhaust channels on the frame. The channels are inverted so the cell terminals face the cold plate instead of the pack housing. This prevents fumes from entering the pack housing. The frame structure and channels isolate and evacuate fumes during thermal runaway, reducing the risk of chain reaction in the pack.

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Battery module design to improve safety against thermal events in battery packs for vehicles. The module has a stack of battery cells surrounded by a case. Each cell has an interrupt member covering part of the cell to prevent thermal propagation if a cell overheats. The interrupt member blocks spread of flames and gases to adjacent cells. It also guides vented materials out of the module to prevent internal fire spread. This mitigates chain reactions and explosions in multicell modules.

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Polymeric composite materials with improved insulation properties while maintaining textural properties. The composite contains a continuous polymer matrix with dispersed aerogel particles. The aerogel particles are organic polymer-based aerogels like polyimide aerogels. Adding the aerogel particles to the composite delays the peak exotherm during curing, increases the deflection temperature, and lowers the composite's thermal conductivity and dielectric constant compared to the unfilled composite. The composite can have applications in insulation for electronics, pipes, buildings, etc.

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Battery pack design to prevent overheating, thermal runaway, and ignition in battery packs for vehicles. The pack has a heat dissipation structure between the batteries and lid that helps dissipate heat generated by the batteries. The structure has contact points on the batteries and lid that maintain a gap. This allows gases to vent between the batteries and lid, preventing accumulation and potential ignition. The heat dissipation structure also has connections between the contact points to maintain the gap. The structure is made of a material with higher thermal conductivity than the lid to efficiently transfer heat. This prevents overheating, suppresses chain thermal runaway between batteries, and improves safety of the battery pack.

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Composite material, composite material layer, and thermal barrier composite for high temperature applications like battery packs. The composite has a silicone matrix, reinforcing filler, and a ceramization filler composition. The ceramization filler contains components that promote ceramization, a flux to aid sintering, and a flame retardant. This enables the composite to form a dense ceramic barrier at high temperatures, improving thermal barrier performance compared to traditional silicone-based materials.

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A flame-resistant, compressible, and heat insulating foam material for lithium-ion battery spacers. The foam contains 35-95% organopolysiloxane, 1-30% fire retardant, and 1-35% hollow ceramic particles with 25-300 μm size. The foam has density 0.10-0.90 g/cm3. The foam provides compressibility, insulation, and flame resistance for battery modules to prevent thermal runaway propagation. The foam can be applied between cells and/or fill spaces between cells and end plates.

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Nonaqueous electrolyte secondary battery design to enhance safety against fire spread in battery modules. The battery has an electrode group with a first electrode wound further outside than the second electrode. The first electrode has an excess portion wound around its outer surface without the separator or second electrode interposed. This exposed portion of the first electrode current collector helps prevent cracking of the battery case and allows gas to vent through the safety valve instead of through cracks. The separator interposed between the electrodes during winding can hinder gas flow and increase cracking.

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Separator for rechargeable lithium batteries that reduces the risk of explosion when the battery overheats by capturing and trapping generated gases. The separator has a coating of metal organic framework (MOF) materials like ZIF-8, Fe-BTC, or a combination thereof on the surfaces. These MOFs have pores that adsorb gases like oxygen and hydrogen generated during battery failure to prevent explosive pressure buildup.

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Battery pack design to mitigate fire risk from volatile electrolyte leakage. The pack enclosure contains absorbent material that traps flammable electrolyte vapor if it leaks from the cells. This prevents the vapor from accumulating and potentially igniting. The absorbent material inside the pack catches any leaked volatile electrolyte components before they can build up and pose a fire hazard.

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Battery Disconnect Unit (BDU) device for battery packs that improves heat dissipation and reliability compared to conventional designs. The BDU has a heat conductive plate that thermally couples the internal heating elements to an external surface. This allows heat to be dissipated through the plate instead of just through the housing. A gap between the BDU housing and the battery pack prevents contact that could deform the housing. The heat conductive plate is compressible to improve stability during installation and contact with the pack.

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Container design to prevent propagation of thermal runaway between electrochemical cells or batteries inside. The container has a molded body and cover made of a high thermal conductivity material. The body has vertical receptacles for the cells and internal walls separating them laterally. The cover has passages above the receptacles for cell portions to protrude. A vent allows gases to escape. Seals between receptacles and headspace are breakable and selectively permeable to prevent matter transfer. This prevents thermal runaway and material spread between cells.

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A secondary battery pack for electric vehicles that improves thermal management to prevent runaway cell temperatures and propagation of thermal events. The pack uses a syntactic foam made of hollow glass beads in a silicone binder to insulate the battery cells. This foam provides better low-temperature insulation compared to standard foams. It also minimizes thermal propagation between cells. The pack can have coolant channels and heat dissipation members to further manage cell temperatures. The syntactic foam also helps dampen drivetrain oscillations.

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Coating battery electrodes with protective thin films to improve safety and thermal stability. The films are formed by a liquid-phase deposition method that involves exposing the electrodes to reacting solutions containing reagents that bond to the electrode surface. The films provide a protective coating that reduces the propensity for batteries to undergo thermal runaway. The films are grown using a conveyance system that transfers the electrodes between reaction chambers for each reactant exposure.

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A traction battery pack assembly with compartmentalized battery arrays and an exhaust system to manage thermal runaway. The battery pack has multiple compartments, each containing a battery array. An intake manifold delivers air to the compartments, and exhaust manifolds remove air. This allows selective heating or cooling of arrays based on conditions. The exhaust system with multiple manifolds prevents hot gases from one array affecting others during venting events.

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Integrated thermal barrier systems for electric vehicle battery packs to mitigate the effects of battery thermal events. The systems include components with foam and endothermic aerogel that can be placed between the battery cells, over sensitive components, or between the cells and bus bars. These components provide a thermal barrier to contain and suppress thermal runaway propagation within the battery pack in the event of a cell failure. The foam and aerogel materials have properties like intumescence and endothermic reaction to absorb and dissipate heat during a thermal event to prevent spread.

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Thermal insulation layer for batteries that prevents excessive heat buildup during thermal runaway to prevent cover damage and fires. The layer has a high lateral thermal conductivity and low axial thermal conductivity, allowing fast heat dissipation in one direction while blocking heat transfer in the other. This prevents heat from reaching high temperatures on the backside that could damage the cover. The insulation layer is applied to the battery pack to protect against cover damage during thermal runaway when the pack's energy density is high enough to generate extreme temperatures. The insulation thickness varies with cell energy density to maintain backside temperatures below 1200°C. The layer has a first surface facing the battery pack and a second surface away from the pack. The insulation material has lower thermal conductivity in the direction parallel to the pack surface (axial) vs. perpendicular to the pack surface (lateral).

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Thermal shock composite material for battery packs that can block solid flames and heat during battery thermal runaway to improve safety. The composite has three layers: a thermal shock resistant composite layer, an expandable insulation layer, and a support layer. The layers are sequentially applied and cured to form a composite with a three-layer structure. The thermal shock resistant composite layer absorbs flame heat and transfers it to the support layer. The expandable insulation layer expands when heated but is supported by the composite layers to prevent collapse. This prevents flame penetration through the composite. The layers prevent heat transfer from the gap to the far end.

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Battery pack design with thermal barriers and exhaust systems to mitigate inter-cell heat spread during battery thermal events like overcharge or short circuit. The design incorporates expandable heat-absorbing airgel sheets integrated into the cell stack and partition assemblies between cell groups. These airgel sheets expand and absorb heat to limit cell-to-cell propagation when temperatures exceed thresholds. The barriers prevent heat spread between cells, while the exhaust systems vent gases and effluents during thermal events to contain the damage.

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Fusible thermal interface material for traction battery packs that limits thermal runaway propagation in electric vehicle batteries. The material is placed between battery cells and heat exchangers. It transitions from conductive to insulative when temperature exceeds a threshold, preventing thermal propagation between cells. This prevents battery thermal events from spreading like a chain reaction. The fusible interface material prevents catastrophic cell-to-cell thermal runaway in packs.

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Thermal barrier assemblies for traction battery packs that prevent thermal runaway propagation between cells and compartments. The barrier has a protective housing and an insulating barrier inside it. The housing can be metal, ceramic, or polymer. The insulating barrier can be aerogel, foam, or inorganic paper. This assembly blocks thermal energy movement between cells to contain thermal events and prevent cell-to-cell propagation.

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Heat transfer member for battery modules that prevents thermal runaway propagation. The heat transfer member contains a thermally expandable material with a specific temperature range. When a battery cell in the module experiences thermal runaway, the expanding material cracks or breaks the heat transfer path between cells or between the module and cooling system. This prevents further spread of thermal runaway. The heat transfer member improves cooling during normal operation but breaks during runaway to prevent propagation.

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A secondary battery pack for electric vehicles that improves thermal management to prevent thermal runaway and propagation between cells. The pack uses a syntactic foam insulation made of hollow glass beads in a silicone binder. This foam provides thermal insulation and minimizes temperature differences between cells. It also has low water absorption to prevent swelling in wet conditions. The pack also has thermal barriers and spacers to isolate cells and prevent thermal propagation. The spacers maintain cell position during thermal events. The pack may also have coolant channels to dissipate heat. This comprehensive thermal management strategy mitigates cell-to-cell thermal effects and risks.

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Battery thermal suppression system for electric vehicle packs that mitigates thermal runaway propagation in battery cells during overcharge, overdischarge, overheating, short circuit events. The system uses aerosol devices integrated into the battery packs. The devices contain ignition and generating components that react to ignite when triggered. The aerosol particles disburse to cool the cells, preventing thermal cascading. The devices can be active or passive and implanted at battery array or pack level.

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High-heat-conductivity semi-solid phase-change heat-insulation composite material for battery modules that can effectively inhibit and delay heat spreading during battery thermal runaway. The composite material has a framework supporting material, a phase-change material, a heat-conducting material, and an insulating packaging material. The phase change material and heat conduction material are fixed in the framework and packaged in insulation. The phase change material absorbs heat from runaway cells and forms a porous insulator after consumption. The framework and gel provide heat conduction and insulation. The composite material delays heat spread and protects adjacent cells.

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Battery module design to delay heat spread and prevent thermal runaway propagation in lithium-ion batteries. The battery module has an outer coating of phase change material that absorbs heat during thermal runaway of individual cells to reduce heat transfer. Ceramic fiber coatings are applied over the phase change material to further slow heat escape. An airgel pad is sandwiched between the ceramic coatings of adjacent cells to further isolate heat transfer. This multi-layer barrier system delays heat spread and gives time for passengers to escape before adjacent cells ignite.

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Protective element for thermal and electrical insulation of batteries to prevent fire and explosions during overheating or short circuits. The protective element is a multilayer structure with a heat-resistant fabric carrier layer and a protective layer made primarily of phlogopite mica. The phlogopite layer delays or prevents flame and spark escape when the battery overheats, reducing fire spread and risk to occupants. The heat-resistant fabric layer prevents melting and rupture of the battery housing. The protective element has a thin overall thickness for compact battery packaging.

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A secondary battery pack for electric vehicles that provides improved thermal management and low temperature insulation. The pack uses a syntactic foam made of a silicone binder and hollow glass beads to fill the space between the cells and cover them. This foam isolates the cells from each other and the pack casing, preventing thermal propagation. It also insulates against low temperatures better than standard foams. The foam can be shaped to fit the pack geometry and replace traditional packing materials. The pack also has heat dissipation members and cooling systems to further manage cell temperatures.

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Mitigating thermal events in energy storage systems like lithium-ion batteries to prevent heat propagation and spread after cells experience thermal runaway. The approach involves adding insulation material between cells to isolate them and reduce heat transfer. The insulation material has properties like compressibility to meet mechanical requirements of the battery pack. It can be made of materials like aerogels, fire retardant additives, and airgel particles. This insulation prevents thermal runaway in one cell from spreading to adjacent cells. It also helps dissipate heat during normal operation.

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Battery design for electric vehicles that improves thermal management to prevent overheating and improve safety. The battery uses thermal barriers between cells that contain an endothermic and intumescent material. This material expands and engages the cell surface as temperature rises, absorbing the heat generated by the cell. The barrier insulator prevents further heat transfer. The expanding material also compresses the insulator and displaces it. This allows the material to further absorb heat when cell temperature increases but the insulator is still present. This prevents insulator consumption by the cell heat. The barriers also have tabs coated with the expanding material. The tabs displace as the expanding material expands, allowing further heat absorption. The battery also has a coolant-releasing microcapsule film over the cells.

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Mitigating thermal runaway propagation in battery packs to prevent chain reactions and catastrophic failures. The method involves using thermal barrier materials in battery modules and packs to prevent heat transfer between cells when one cell experiences thermal runaway. The barrier material can have higher thickness, volume, etc. compared to normal battery components to provide sufficient insulation. This prevents adjacent cells from overheating and initiating thermal runaway themselves.

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A secondary battery pack with improved thermal management to prevent propagation of thermal runaway between cells and minimize the effects of extreme temperatures. The pack uses a specific syntactic foam made of silicone rubber binder and hollow glass beads. This foam is sandwiched between the battery cells to insulate them from each other and the pack enclosure. It also absorbs thermal energy to reduce temperature spikes. The foam has low water absorption to prevent swelling in wet conditions. The pack may also have thermal management features like cooling channels, heat sinks, and spacers to further isolate cells and dissipate heat.

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Reducing thermal energy transfer between battery arrays of a battery pack to prevent venting during high temperature events. The technique involves using a phase change material (PCM) sandwiched between adjacent battery arrays and a thermal exchange device like a liquid coolant channel. The PCM absorbs excess heat from one array to prevent it transferring to the other array. This prevents one array overheating and venting due to thermal runaway, as the PCM acts as a thermal barrier. The PCM can be adhesively secured to the thermal exchange device.

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Secondary battery pack for electric vehicles with improved thermal management, low temperature insulation, and damping control. The pack contains a syntactic foam made of silicone rubber and hollow glass beads that fills the spaces between the battery cells and modules. This foam insulates the cells from each other and prevents thermal propagation. It also isolates the cells from low temperatures. The foam can be made with specific viscosities and compositions to fill the pack and surround the cells.

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High temperature resistant heat insulation board for lithium batteries that improves heat dissipation to prevent thermal runaway and catch fires. The board has a vacuum chamber between metal films filled with a composite core material containing adsorbent. The vacuum prevents convective heat transfer. The adsorbent absorbs water vapor and cools by releasing latent heat during desorption.

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Composite material for battery boxes that provides high temperature resistance and prevents thermal runaway propagation while keeping weight low. The composite has layers in sequence from inside to outside: an inner heat insulation layer, a heat-resistant resin layer, and a supporting resin layer. The heat-resistant resin layer prevents fire spread, while the supporting resin layer provides mechanical strength. The composite materials coordinate to delay fires and prevent structure collapse after battery runaway. The inner heat insulation layer further reduces temperatures around the battery.

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High temperature insulative composite materials for protecting electronic devices and components from high temperatures without melting or degrading. The composites have a fibrillated polymer matrix containing aerogel particles, opacifiers, and reinforcement fibers. The fibrillated polymer matrix enmeshes the fillers durably without binding binder. The composites have low thermal conductivity at room temperature. When exposed to high temperatures, the fibrillated polymer volatilizes leaving the fillers behind as a heat barrier. This prevents heat propagation and protects adjacent components. The composites are thin, flexible, and conformable for use in applications like batteries where high temperatures can occur.

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Reducing thermal energy transfer between battery arrays in a battery pack to prevent thermal runaway propagation. The method involves placing battery arrays adjacent a thermal exchange device and securing a phase change material to the device. The phase change material absorbs thermal energy from one array instead of allowing it to transfer to adjacent arrays. This prevents chain reactions and venting in other arrays during high temperature events. The thermal barrier in the exchange device further isolates adjacent arrays.

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Power supply device for batteries that reduces thermal propagation (fire spread) between cells and allows adaptability to swelling. The device uses separators made of flexible, heat insulating materials with restoring force. The separators deform when pressed by cells but recover shape to prevent thermal runaway spread. They have mesh structures or coatings to allow air pockets for insulation. This prevents fire propagation between cells while accommodating cell swelling.

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Cure-in-place, lightweight, thermally conductive interface between a thermal energy source like a battery and adjacent structures to prevent thermal runaway propagation. The interface has a thermally conductive foam pad with filler material like graphite or boron nitride. The foam pad is disposed between the battery and adjacent components like other batteries. It absorbs and conducts heat from the battery to prevent neighboring batteries from overheating if one enters thermal runaway. The foam pad density is below 0.5 g/cm3 for lightweight contact with the batteries.

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Adaptive thermal management system to mitigate lithium battery thermal runaway during parking. The system uses a combination of early warning, isolation, and fire suppression to address thermal runaway in parked electric vehicles. It integrates a phase change material to store heat during normal operation, but melts during runaway and transfers heat to a shape memory alloy spring to trigger isolation. This isolates the runaway battery from the pack. The system also has an alarm device to notify occupants and a fire suppressant to extinguish any flames.

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Thermal barrier coating for battery pack vent ducts in electric vehicles to prevent heat transfer from expelled battery vent gases. The coating blocks heat emitted by battery vent byproducts during cell venting events. This prevents heat from the vent gases transferring to other components in the vehicle and helps contain thermal runaway. The coating can be applied to the inside and/or outside of vent ducts in the battery pack. Additionally, a separate thermal barrier can be applied to nearby vehicle components to further improve containment.

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Thermal management for batteries that allows neighboring cells to thermally isolate from each other during thermal runaway to prevent propagation. It uses an expandable composite material with intumescent particles that expands and delaminates from the interface between cells and heat sinks when heated above a threshold. This creates a thermal barrier to isolate cells and prevent runaway propagation. The expandable material has low thermal conductivity normally but expands and delaminates during runaway to prevent heat transfer.

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A battery pack design with improved thermal management for electric vehicles. The pack uses a specific syntactic foam material made of hollow glass beads in a silicone matrix. This foam insulates the battery cells from external temperature extremes and minimizes propagation of thermal excursions within the pack. It also dampens vibrations to reduce noise. The foam is made by crosslinking a silicone rubber binder with the hollow glass beads. The foam is sandwiched between the cells and covers the pack sides to provide thermal isolation. The pack also has thermal management features like coolant channels and heat dissipation members to further control temperatures.

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Battery protection system using inorganic phase change materials (IPCMs) that absorb heat during thermal events exceeding 100°C to mitigate catastrophic failures. The IPCMs have high heat absorption during solid-solid or solid-liquid phase changes at elevated temperatures. They are included in the battery packaging, coated on surfaces, or mixed with separators to absorb excessive heat during battery thermal runaway. The IPCMs prevent flammability risks and expansion issues compared to organic PCMs. They remain solid during phase changes and don't vaporize water like salt hydrates. The IPCM formulations can be powders, granules, pellets, sheets, or composites.

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A modular composite structure for thermal management of enclosed volumes like battery packs. The structure contains phase change materials (PCMs) encapsulated in a rigid matrix. The PCMs change phase at specific temperatures to absorb or release heat. Channels are formed between the PCMs by cutting the matrix. Fluid like air or coolant can circulate through these channels to manage the enclosed volume temperature. The rigid matrix prevents PCM dispersion when liquid. It also provides structural support and thermal performance.

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Heat management system for batteries in electric vehicles that uses phase-change materials and conduction paths to efficiently transfer heat without adding components like coolant loops or fans. The system involves attaching a first phase-change material element to one end of the battery, and a second phase-change material element to other parts of the battery and a bracket. The elements transfer heat to the vehicle structure and a heat sink. The elements' melting points differ, enabling efficient heat transfer. This allows natural convection and conduction cooling without adding parts, coolant, or power consumption.

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Fire prevention system for battery packs in electric vehicles to prevent propagation of thermal runaway between cells. It uses a multi-layer barrier with anisotropic thermal materials to capture and absorb heat released by a runaway cell, preventing it from spreading to adjacent cells. The barrier has a structure to separate modules and a thermally anisotropic material between them. The material has high in-plane thermal conductivity but low through-plane conductivity. This allows heat to be transferred away from a venting cell but not through the barrier.

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Battery pack design for preventing or delaying thermal runaway during battery thermal events. The battery pack has a passive thermal suppression material system positioned around the battery system. The suppression material releases during certain battery thermal events to prevent or delay thermal runaway inside the pack. The suppression material can be encapsulated in a slip cover or sandwiched between polymer films to contain it. The polymer films are made of low melting point polymers that melt and release the suppression material during thermal events. This helps prevent propagation of thermal runaway between battery cells.

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