Thermal Barriers to Mitigate Thermal Runaway

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.