Thermal Propagation Prevention Methods for EV Battery Packs

Battery pack design to prevent thermal runaway propagation between modules. The pack has a resistance element inside each module that converts electrical energy into heat when thermal runaway occurs. This prevents further runaway by consuming the module's power. A heat insulating material surrounds the resistance element to reduce heat transfer. A heat dissipating component connects to the pack housing to conduct the heat out. This prevents accumulation and reduces propagation risk. The dissipating component extends into the pack housing sides to discharge heat outside.

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A battery module comprising a cell assembly, a module case with an open surface, and a filling part made of an electrically insulating and fire-resistant material that fills the empty space between the busbar assembly and the module case. The filling part replaces a separate insulating member and prevents thermal propagation between adjacent cells during thermal runaway.

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Active thermal management system for batteries that allows extended life and performance outdoors by actively removing heat from the batteries. The system uses thermal conduits and thermoelectric coolers to transfer heat from the batteries to external coolers. This prevents environmental heat from getting into the batteries and allows precise control of battery temperature. It also prevents explosive venting by isolating degraded cells. The system allows long-term outdoor operation of batteries without maintaining insulation or maintaining battery pack temperatures in extreme environments.

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A thermal management system for batteries and other electrical components that passively circulates a working fluid between panels to maintain optimal operating temperatures. The system uses sealed panels with internal passages filled with a working fluid that changes phases between liquid and vapor. Heat is transferred through evaporation in one area and condensation in another. This allows uniform temperature distribution across the panels without pumps or external fluids. A heat exchanger connects to the panels to communicate heat with the component. The sealed system can be heated by a fluid pump or cooled by a low temperature storage device.

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A battery pack with integrated thermal management system, comprising an enclosure with interconnected walls, battery cells, a battery management system, and a heat-conducting plate defining one or more walls. The heat-conducting plate has a first section in thermal contact with the battery cells and management system, and a second section in thermal contact with the first section and the environment outside the enclosure. The system enables efficient heat transfer between the battery cells, management system, and environment, maintaining optimal operating temperatures.

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An energy storage assembly and battery unit that improves thermal management and electrical conductivity between energy storage cells and conductive members. The assembly features a thermally conductive and electrically insulating thermal interface material that fills irregularities on the cell terminals and conductive interfaces, enabling efficient heat transfer and electrical conduction. The thermal interface material is applied through a needle injection process or spot welding, eliminating the need for high-temperature welding techniques that can damage cell terminals.

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Thermal management system for power systems like vehicles that uses a compact housing with internal passages to exchange thermal energy between devices and a fluid. The housing has multiple orthogonal passages extending from one end to the other. Fluids are directed into and out of specific passages to control thermal conditions of devices within the housing. The fluid can be recycled or expelled. The housing shape allows densely packing devices while the internal passages isolate them. A controller adjusts fluid flow based on sensor data to balance device temperatures.

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Battery module with integrated heat sink that enables direct cooling between the cell stack and module frame. The module features a frame with a protruding bottom section that passes through the end plates, allowing the refrigerant to flow directly from the heat sink to the cell stack. This integrated design eliminates the conventional separate cooling structure, with the heat sink forming a continuous path from the bottom of the frame to the cell stack. The end plates incorporate an opening that matches the cooling port, and an insulating cover prevents refrigerant leakage. This configuration enables efficient cooling through direct flow between the cell stack and frame, while maintaining the conventional battery cell stack structure.

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A battery with enhanced thermal management performance, comprising a battery cell with a thermally conductive member thermally connected to its first wall, and a partition plate extending along the second direction and connected to the first wall of each battery cell, to facilitate heat exchange and prevent thermal runaway.

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A battery system with thermal management design for electric vehicles and other applications, featuring an enclosure with high thermal insulation capability to maintain battery temperature within a safe operating range. The enclosure includes a thermal insulation unit with a vacuum layer and a structural unit, and is designed to reduce temperature differences among battery cells. The system also employs a heat exchange pipe with a metal outer tube for efficient heat transfer, and a system fluid circulation device with a temperature control medium that is conditioned outside the battery device before being introduced for heat exchange.

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A battery module with enhanced electrical safety performance, comprising a battery cell array, a side plate, and an insulation barrier. The side plate is circumferentially arranged on the outer side of the battery cell array in a sealing manner, and the insulation barrier is positioned between the side plate and the battery cell array, protruding above the battery cell array to increase the creepage distance between the battery cell housing and conductive parts on the outer side of the side plate.

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Power supply device with a battery block and case that incorporates a heat-generating component, featuring a mesh area with air holes for cooling and an expansion chamber for ejected material from the battery cells. The ejected material flows through a guide gap and undergoes adiabatic expansion before being discharged through the air holes, while cooling air is blown onto the battery block surface. The device also includes a blower fan that can blow cooling air into the guide gap and exhaust air from the air holes to enhance cooling performance and prevent external flames.

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A battery module thermal management system that uses a combination of flowing coolant and highly-thermally-conductive inserts to transfer heat out of the module. The inserts are placed between battery cells to direct heat towards the top of the module, where it is absorbed by liquid cooling channels. This approach enables more efficient heat removal from the center of the module, where heat tends to accumulate, and maintains a more uniform temperature across the battery cells.

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Battery design with multiple discharge channels to improve safety by preventing chain reactions. The battery has multiple battery cells with pressure relief mechanisms. Each cell discharges into a separate channel instead of a single channel. This prevents emissions from multiple cells blockading the channel. When a cell fails, emissions discharge into a channel, reducing risk of further cell failures. The channels are spaced apart to prevent cross-contamination. The channels can lead to external locations. This allows failure gases to escape quickly and safely, reducing internal pressure and temperature. It also prevents solid debris from blocking the channels.

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Battery design to prevent thermal runaway during high-temperature discharge. The battery incorporates a first cell with a pressure relief mechanism that releases gases during thermal failure, while a second cell features a pressure relief mechanism that releases gases during thermal failure but at a lower temperature. This design prioritizes the prevention of thermal runaway in the first cell, thereby ensuring battery safety and preventing chain reactions that can lead to thermal failure.

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Battery design with improved thermal management to prevent overheating and damage. The battery has a unique cell-thermal management component interface. The component has an accommodating portion that attaches to the cell's bottom and side walls. This allows the cell to extend partially or fully into the component. This increases the surface area for heat transfer between the cell and component compared to just the bottom contact in conventional batteries. This enables better dissipation of cell heat into the component fluid, preventing excessive temperatures and damage.

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A battery pack with improved thermal runaway safety, comprising a battery box body, a pressure relief structure, a first battery assembly, and a reinforcement member. The reinforcement member is positioned between the battery box body and the first battery assembly, and includes a gas guiding channel with an opening that aligns with the pressure relief structure. This configuration enables timely opening of the pressure relief structure during thermal runaway, allowing safe discharge of generated gases.

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Vehicle battery fire sensing apparatus and method to accurately and rapidly detect battery fires in electric vehicles. Sensors outside the battery pack case measure temperature and pressure of discharged gases. These values are directly transmitted to the ECU instead of through the battery management system. This allows rapid fire detection even if sensors or the BMS inside the pack fail. By bypassing the BMS, the ECU can receive timely fire alerts from the pack exterior sensors.

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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 box design for electric vehicles that improves safety by preventing adhesive cracking during temperature cycling. The batteries inside the box are bonded to the case walls using an adhesive with a specific thermal expansion-to-conductivity ratio. The ratio is 15-80, where the expansion matches the case walls' expansion more closely than the conductivity matches the case walls' conductivity. This prevents cracking when the batteries and case expand/contract at different rates due to temperature changes.

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Battery module that enables high-temperature operation of lithium-ion batteries by optimizing their internal resistance profile. The module comprises two cells of different chemical systems, where the cells are connected in series. The cells' internal resistance profiles are optimized to achieve a specific impedance ratio between the alternating current (AC) and direct current (DC) impedances. This enables the first cell to generate more heat than the second cell when charging, while the second cell benefits from the second cell's increased heat dissipation capability when discharging.

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A battery pack for electric vehicles that integrates a heat-conducting plate into the structural frame of the pack. The plate has two sections: one in direct thermal contact with the battery cells, and another exposed to the environment for heat exchange. The plate's structural load-bearing capability enhances the pack's overall stiffness while providing efficient thermal management.

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An electrode group for a battery that enables excellent cycle life and rapid charging performance in low-temperature environments. The electrode group comprises a positive electrode and a negative electrode with a specific area-to-thickness ratio (6500≤A/B≤18500) that balances heat generation and dissipation. The negative electrode contains a titanium-containing composite oxide, such as monoclinic niobium titanium oxide or orthorhombic titanium oxide, which enables high capacity and low insertion potential. This design enables the battery to maintain performance in cold temperatures while preventing thermal degradation and resistance increases.

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Battery pack with swelling control structure, comprising a plurality of battery modules, a pack tray, a module cover, a pack cover, and an upper elastic member. The elastic member is compressed between the module cover and pack cover, absorbing volume expansion due to swelling of the battery modules. The pack tray accommodates the battery modules, and the module cover covers the pack tray opening. The pack cover covers the module cover, and the elastic member maintains constant pressure on the battery modules as swelling increases.

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Battery pack with improved thermal runaway prevention and space utilization. The pack features a battery box with a main body and top cover, where the battery's pressure relief structure and terminal assembly are located on the same side and face the bottom surface of the main body, rather than the top cover. This design prevents gas discharge from the pressure relief structure from directly ejecting towards the top cover and passenger compartment, while also optimizing space utilization within the battery box.

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Box design for battery packs with improved safety and cooling. The battery pack has a separate chamber for collecting emissions when a cell vents, isolated from the cell chamber. A thermal management component connects both chambers. When a cell vents, emissions flow through the isolation component to discharge externally. This extends the emissions path, reducing temperature and external impact. It also prevents internal shorts from vapors.

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Battery thermal management system that uses a melting plug to quench overheating batteries and prevent thermal runaway. The system has a reservoir of quenching material, a distribution system to carry it, and a melting plug that melts at a specific temperature. When a battery overheats, the plug melts and releases the quenching material into the battery pack to cool it down and prevent runaway. This provides an active cooling mechanism that can be triggered when needed to mitigate overheating issues in batteries.

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Charging lithium metal batteries with ultrasonic vibration to prevent dendrite formation and improve charging efficiency. The method involves applying ultrasonic vibrations to the lithium metal negative electrode during charging. This softens the metal and reduces inhomogeneities that can cause dendrites. It also redistributes lithium ions to improve contact with the electrolyte and current collector.

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Battery pack exhaust duct design to improve particle collection efficiency and prevent ignition and smoke in battery packs. The duct has multiple internal guide components that meander along the tube to collect particles from the exhaust. This reduces the risk of ignition and smoke outside the pack by removing hot particles before they exit. The guide components have sections that extend away from the tube wall toward the inlet and sections that extend back toward the wall. The sections with different end positions along the tube axis prevent particles from bypassing the guides. The meandering path also lowers exhaust temperature and pressure to further prevent ignition.

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Direct cooling of battery cell tabs using a multi-material cooling module that provides improved cooling efficiency and reduced size compared to conventional liquid cooling systems. The cooling module has an isolation sheet with a planar surface contacting the cell tabs, and a heat exchanger inside with a lightweight thermally conductive plastic portion and a metallic portion. Baffles extending from the plastic portion create a serpentine flow path. The plastic portion provides lightweight flexibility while the metallic portion provides rigidity. This allows the module to conform to the cell tab shapes and directly contact them for cooling, without needing separate tubing or channels. The module compressively engages the cell tabs and interconnect boards using an ICB cover. The baffles can have metallic members to form thermal bridges.

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Thermal management system for electric vehicles that uses a bypass and switching mechanism to optimize cooling of the battery pack based on temperature. The system has a radiator and a chiller connected by a valve. The valve can be positioned to selectively bypass the radiator and use only the chiller, or vice versa. A controller monitors battery temperature and switches the valve position when needed to prioritize cooling based on temperature conditions. This allows more aggressive cooling when needed to prevent overheating, but also bypasses the chiller when not necessary to save energy compared to continuous chiller operation.

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A battery module with optimized structure and connection arrangement. The module includes a jumper electrode connector, a first battery, and a second battery, with an insulating structure between the jumper and batteries. The jumper and insulating structure are positioned to enable efficient electrical connection while preventing short circuits. The module's design allows for flexible configuration of the battery connection relationship, including series and parallel connections.

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A battery sub-packing unit and module that prevents secondary battery cell ignition propagation and shields cells from heat transfer. The unit comprises a cell support member with a seating portion for multiple cells, a venting inducing portion, and a case member that surrounds and seals each cell. The module integrates multiple sub-packing units within a body frame member. The design enables flame containment and extinguishment when a cell is ignited, preventing heat spread to adjacent cells.

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A fire suppression system for electrochemical units in vehicles, comprising a gas detector, control unit, and fire extinguishing fluid container. The system detects gas emissions from the electrochemical unit and compares them to pre-set thresholds, discharging fire extinguishing fluid when a threshold is exceeded. The system can also receive temperature data from the vehicle's computer system and trigger discharge based on both temperature and gas thresholds.

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All-solid-state battery with improved stability and reduced interfacial resistance compared to conventional all-solid-state batteries. The battery has a thin contact layer sandwiched between the anode and solid electrolyte to prevent cracks in the solid electrolyte during charging. The contact layer is a thin metallic layer like lithium that can accommodate localized lithium plating from the anode without forming cracks in the solid electrolyte. This reduces the risk of short circuits and improves battery stability. The contact layer also reduces the interfacial resistance between the anode and solid electrolyte compared to direct contact.

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A battery module with enhanced thermal protection and propagation prevention. The module includes a thermal compensation element positioned between each battery cell and a tensioning element, with the tensioning element connected to a heating element on its opposite side. This configuration enables reliable thermal decoupling between cells and prevents heat propagation in the event of thermal runaway. The thermal compensation element can be a heated woven fabric or a thermally conductive paste, and is designed to maintain electrical insulation while ensuring effective heat transfer.

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Energy storage module with enhanced fire safety through a novel design that prevents thermal runaway in lithium-ion batteries. The module features a cover with a protruding duct that surrounds the battery cells' vents, creating a fire-resistant barrier. An integrated extinguisher sheet positioned between the cover and top plate emits a controlled fire suppression agent at a reference temperature, effectively containing the fire when it occurs. This design addresses the challenges of fire spread in lithium-ion batteries by preventing the spread of thermal energy through the duct and vent system.

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A battery module with improved cooling performance, comprising a battery cell stack, a housing with a heat sink on its bottom, and a cooling port for refrigerant supply and discharge. The housing features protrusions on either side of the heat sink, with the cooling port located on these protrusions. This design enables efficient heat transfer and refrigerant circulation, enhancing cooling performance in high-temperature applications.

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An electronic device with a battery pack stack comprising at least two battery packs, where at least one cumulative heat reducing component is positioned between the battery packs to minimize heat buildup and extend battery lifespan. The component can be a heat conductive film, heat insulating film, phase change material, or other thermal management solution. Alternatively, the battery packs can be positioned in an offset orientation to reduce thermal gradients.

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Battery pack design to prevent thermal runaway propagation and improve pack robustness. The design uses thermal insulation between cells, but also allows heat transfer between blocks. It uses beams to hold the cell blocks and a bypass busbar to electrically connect blocks. The insulation compresses to accommodate cell swelling. This allows compact packs with better heat dissipation compared to rigid insulation. The bypass busbar isolates failing blocks while allowing heat transfer to spread through the pack.

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A battery module element for a battery module, comprising a housing element with an electrical circuit board on one side and an inductance mechanically arranged on the circuit board with one end extending through the board and thermally connected to the housing. The housing has a temperature control structure on the opposite side, allowing temperature control fluid to flow around it, with flow guide and disruption elements to enhance cooling.

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Electrical power systems for aircraft propulsion that utilize metal foam bus bars to connect battery cells or fuel cells, enabling improved thermal management and reduced weight compared to conventional solid metal bus bars. The metal foam bus bars create turbulent flow of cooling fluid, enhancing heat transfer and allowing for more efficient cooling systems. The bus bars can be integrated with various cooling systems, including forced air devices and heat exchangers, to manage heat generated by the cells. The metal foam bus bars can also be designed with varying densities and configurations to optimize thermal performance and electrical conductivity.

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Battery pack design to mitigate thermal runaway and improve safety of electric vehicles. The pack has a sealed enclosure with vents that direct expelled gases away from the pack during runaway. The vents guide the gases upwards instead of outwards, preventing them from impacting passengers above or spreading laterally. The pack also has an explosion-proof exhaust structure on the cover that expels the gases out of the pack. This prevents the gases from burning components inside the pack or causing secondary hazards.

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Battery heat exchanger with alternating fluid flow passages for improved temperature uniformity across the heat exchanger surface. The heat exchanger has primary passages for contacting the battery cells and secondary passages that alternate between the primary passages. The fluid flow direction in the primary passages is opposite to the secondary passages. This alternating flow configuration helps distribute coolant temperature more evenly across the heat exchanger surface compared to traditional single-pass layouts.

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A power battery pack for electric vehicles that prevents accumulation of discharged gases inside the pack. The pack includes a battery tray with an air passage network that receives gases from individual battery cells through corresponding inlet vents. An exhaust vent discharges the gases from the air passage, while a battery-pack anti-explosion valve controls gas release. The design enables safe and efficient management of gases generated during battery operation.

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Battery pack design featuring a novel structural configuration that enables efficient cell arrangement while maintaining thermal management. The pack comprises a base member with a bottom wall and a cover member that defines a channel between them. The cover member has apertures exposing battery cell terminals, and a lateral member divides the channel into compartments. The base member and cover member are tensioned when the cell compartments contain a row of cells extending from the base member to the cover member. This configuration enables precise cell alignment while maintaining thermal stability through the lateral member's division of the channel.

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Battery pack design that enhances safety through controlled gas migration during thermal events. The pack comprises a battery housing containing multiple battery cells, each with a vent that directs discharge outward during thermal runaway. The pack includes a plate structure with flow guides and occluding members that direct vapor release from cell vents to an external environment while preventing material discharge from cell vents. This design enables controlled release of gases during thermal events while preventing material migration into the pack.

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A battery with enhanced safety features, comprising a plurality of battery cells, at least one of which includes a pressure relief mechanism that releases internal pressure when a threshold is reached. The pressure relief mechanism is positioned on a side of the battery cell opposite to the electrical bus component, allowing emissions to be directed away from the electrical connections when the mechanism is activated. The battery also includes a thermal management component and a protective member that work together to contain and dissipate the released pressure.

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A cooling system for batteries that integrates thermal management directly into the battery housing, eliminating the need for external cooling systems. The system comprises a thermally conductive battery housing that is inserted into a battery compartment, where it is surrounded by a thermal element. This design enables passive cooling of the battery, preventing overheating during prolonged operation and enabling rapid charging after use.

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A storage battery device that efficiently cools current flow path members, enables miniaturization, and achieves high voltage and power output. The device includes a cell unit comprising multiple electric cells, current flow path members forming the power flow path, and a radiator thermally coupled to the current flow path members.

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