Thermal Barriers for EV Battery Protection

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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