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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