DESC:“AN ENERGY STORAGE SYSTEM AND METHOD FOR THERMAL MANAGEMENT AND THERMAL RUNAWAY PROPAGATION MITIGATION”

FIELD OF THE INVENTION
The present disclosure relates to energy storage devices and more particularly to an energy storage system and method for thermal management and thermal runaway propagation mitigation in the energy storage system. The present application is based on, and claims priority from an Indian Provisional Application Number 202341022561 filed on 28-03-2023, the disclosure of which is hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION
The energy storage system includes one or more cells. As used herein, a cell is a device that stores chemical energy and converts into electrical energy. The temperature of the one or more cells may increase while charging and discharging which will heavily impact the temperature level of the energy storage system.
An atmospheric temperature also impacts the temperature level of the one or more cells and the energy storage system. Increased temperature levels of the energy storage system may lead to a fire accident and thermal runaway in the worst scenario. Maintaining the temperature level of the energy storage system with optimal temperature is a difficult task.
In a conventional approach, automobile or electric vehicle manufacturer use a coolant method, a natural heat transfer method, or a passive heat transfer method which reduces the temperature level of the cell and the energy storage system, but this method makes the system big, complex, and expensive.
In other conventional approaches, automobile or electric vehicle manufacturers use an encapsulation technique to restrict thermal distribution among the one or more cells. In the encapsulation technique, an encapsulation structure covers individual cells (of the one or more cells) entirely. So that, there will be a high chance of thermal traps which may increase the temperature level of the one or more cells. The increased temperature level of the one or more cells may lead to a thermal runaway. So, the conventional approaches are not efficient to solve above mentioned problems.
Hence, there remains a need for an improvised energy storage system for thermal management and thermal runaway propagation mitigation and there for address for mentioned issues.

SUMMARY OF THE INVENTION
Accordingly, embodiments herein disclose an energy storage system for thermal management and thermal runaway propagation mitigation. The energy storage system includes one or more cells, a thermally insulative structure, a first layer, and a second layer. The one or more cells are placed on a bottom casing of the energy storage system. The one or more cells include a first predetermined height. A thermally insulative structure is positioned around the one or more cells and is configured to cover a circumferential surface of the one or more cells partially to avoid heat distribution to the one or more cells. The thermally insulative structure includes a second predetermined height. The first layer faces an axial and circumferential surface of the one or more cells. The first layer is configured to reduce heat of the one or more cells by transferring heat to the plurality of fins. The first layer is configured to resist movements of the one or more cells. The first layer is filled inside the bottom casing to a third predetermined height. The third predetermined height depends on the heat generated by the one or more cells or the energy storage system. The second layer is configured to prevent thermal runaway propagation mitigation and reduce shock and vibration. The second layer faces the circumferential surface of the one or more cells to dissipate the heat of the one or more cells. In one embodiment, the thermally insulative structure is a less dense material. The less dense material includes polyethylene foam, foam, and polyurethane foam. In some embodiments, the thermally insulative structure includes a phyllo silicate. In some embodiments, the system further includes one or more cell holders. In some embodiments, the first layer includes resin, polymeric/non-polymeric material, polyurethane, epoxy, and silicon. In some embodiments, the second layer includes a thermal runaway propagation mitigation material, a high heat capacity, and an electrically insulative material. The thermal runaway propagation mitigation material, the high heat capacity, and the electrically insulative material include silicon foam, foam, polyurethane foam, polyurethane, polystyrene, silicon, and poly is ocyanurate. In some embodiments, the first predetermined height of the one or more cells is higher than the second predetermined height of the thermally insulative structure. In some embodiments, each cell of the one or more cells includes a covered portion that is covered by the thermally insulative structure and one or more uncovered portions that are not covered by the thermally insulative structure. In some embodiments, the second predetermined height of the thermally insulative structure is constructed in a manner that the thermally insulative structure covers the one or more cells partially. At least one of the first layer and the second layer are face uncovered axial and circumferential surface of the one or more cells to dissipate heat. In some embodiments, the system further includes a third layer. The third layer is dispensed above the second layer. The third layer includes silicon, foam, polyurethane, polystyrene, and poly is ocyanurate.
Accordingly, embodiments herein disclose a method of thermal management and thermal runaway propagation mitigation. The method includes the following steps: (a) placing one or more cells on a bottom casing of the energy storage system, (i) the one or more cells includes a first predetermined height; (b) covering, by positioning the thermally insulative structure, a circumferential surface of the one or more cells partially to avoid heat distribution to the one or more cells, (i) the thermally insulative structure includes a second predetermined height, (ii) the first predetermined height of the one or more cells is higher than the second predetermined height of the thermally insulative structure; (c) pouring a first layer into a bottom casing to a third predetermined height, (i) the third predetermined height depends on heat generated by the one or more cells, or the energy storage system; and (d) dipping, using a jig, a bottom cell holder, and the one or more cells into the bottom casing of the energy storage system in a manner that at least one of the first layer, the second layer and the third layer faces an uncovered axial and circumferential surface of the one or more cells. In another approach, embodiments herein disclose a method of thermal management and thermal runaway propagation mitigation. The method includes the following steps: (a) placing one or more cells on a bottom casing of the energy storage system, (i) the one or more cells include a first predetermined height; (b) covering, by positioning the thermally insulative structure, a circumferential surface of the one or more cells partially to avoid heat distribution to the one or more cells, (i) the thermally insulative structure includes a second predetermined height, (ii) the first predetermined height of the one or more cells is higher than the second predetermined height of the thermally insulative structure; (c) placing the first cell holder, and the one or more cells into the bottom casing of the energy storage system; and (d) pouring the first layer to the predetermined height of the bottom casing of the energy storage system. In one embodiment, the method further includes the following step: placing a cooling system on top of an interconnector to absorb the heat of the energy storage system. The interconnector is positioned between the second layer and the cooling system. In some embodiments, the method further includes the following step: dipping, using a jig, a first cell holder, and the one or more cells into the bottom casing of the energy storage system in a manner that at least one of the first layer, the second layer, and the third layer faces an uncovered axial and circumferential surface of the one or more cells. These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the invention thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS
This invention is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
FIG. 1 illustrates a side view of a cell of one or more cells according to an embodiment herein;
FIG. 2 illustrates a cross-sectional view of an energy storage system with a first layer, and a second layer according to an embodiment herein;
FIG. 3A, 3B, 3C & 3D illustrate a cross-sectional view of the energy storage system with one or more uncovered portions of the one or more cells in the one or more layers, according to an embodiment herein; and
FIG. 4 is a flow diagram illustrating a method of thermal management and thermal runaway propagation mitigation, according to an embodiment herein.

DESCRIPTION OF THE INVENTION
In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.
The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will be provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth.
The word “exemplary” and/or “demonstrative” is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as “exemplary” and/or “demonstrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms “includes,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive—in a manner similar to the term “comprising” as an open transition word—without precluding any additional or other elements.
Reference throughout this specification to “one embodiment” or “an embodiment” or “an instance” or “one instance” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any alterations, equivalents and substitutes in addition to those which are particularly set out in the accompanying drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.
Accordingly, embodiments herein disclose an energy storage system for thermal management and thermal runaway propagation mitigation energy storage system. The system includes one or more cells, a thermally insulative structure, a first layer, and a second layer. The one or more cells are placed on a bottom casing of the energy storage system. The one or more cells include a first predetermined height. A thermally insulative structure is positioned around the one or more cells and is configured to cover a circumferential surface of the one or more cells partially to avoid heat distribution to the one or more cells. The thermally insulative structure includes a second predetermined height. The first layer faces an axial and circumferential surface of the one or more cells. The first layer is configured to reduce heat of the one or more cells by transferring heat to the plurality of fins. The first layer is configured to resist movements of the one or more cells. The first layer is filled inside the bottom casing to a third predetermined height. The third predetermined height depends on the heat generated by the one or more cells or the energy storage system. The second layer is configured to prevent thermal runaway propagation mitigation and reduce shock and vibration. The second layer faces the circumferential surface of the one or more cells to dissipate the heat of the one or more cells.
Referring now to the drawings and more particularly to FIGS. 1 to4, where similar reference characters denote corresponding features consistently throughout the figure, these are shown as preferred embodiments.
FIG. 1 illustrates a side view of a cell of one or more cells 102 according to an embodiment herein. As used herein, a cell is a single-unit device that converts chemical energy into electric energy. The one or more cells 102 are placed on a bottom casing of an energy storage system. In one embodiment, the one or more cells 102 may include, but not limited to, nickel cadmium, alkaline, nickel metal hydride (NIMH), lithium-ion, nickel hydrogen, lithium iron phosphate or lithium Ferro phosphate, nickel-zinc, electro-chemical cells, sodium ion, and the like. The one or more cells 102 may include a first predetermined height. In one embodiment; the first predetermined height may be varied based on an application in which the one or more cells 102 are used. Each cell of the one or more cells 102 includes a covered portion that is covered by a thermally insulative structure 104 and one or more uncovered portions that are not covered by the thermally insulative structure 104. The thermally insulative structure 104 is positioned around the one or more cells 102 and is configured to cover a circumferential surface of the one or more cells 102 partially to avoid heat distribution to the one or more cells 102. The one or more cells 102 will be placed inside the energy storage system. The number of cells that are present in the energy storage system may vary based on desired output rating of the energy storage system.
The thermally insulative structure 104 includes a second predetermined height. In one embodiment, the second predetermined height of the thermally insulative structure 104 may be varied based on the first predetermined height of the one or more cells 102. In another embodiment, the first predetermined height of the one or more cells 102 will be higher than the second predetermined height of the thermally insulative structure 104. In another embodiment, the thermally insulative structure 104 may be a coating, a sheet, a layer, a block, and the like. The thermally insulative structure 104 is positioned around the one or more cells 102 to avoid heat distribution to the one or more cells 102 by using one or more joining processes.
In one embodiment, the one or more joining processes may be an adhesive, tight fit, and the like. In one embodiment, the thermally insulative structure 104 may be a less dense material with high specific heat. In an embodiment, the less dense material may include, but not limited to, polyethylene foam, foam, and polyurethane foam. In one embodiment, the thermally insulative structure 104 may include, but not limited to, phyllosilicate. The thermally insulative structure 104 includes thermally insulative, and electrically insulative properties.
FIG. 2 illustrates a cross-sectional view of the energy storage system200 with a first layer 204, and a second layer 206 according to an embodiment herein. The cross-sectional view discloses the one or more cells 102 are placed inside the energy storage system 200. The number of cells that are present in the energy storage system200 may be varied based on the desired output rating of the energy storage system 200. The energy storage system200 includes a bottom casing (not shown in the figure), a first cell holder 202, the first layer 204, the second layer 206, and a top casing (not shown in the figure).
The first layer 204 may include, but not limited to, resin, polymeric/non-polymeric material, polyurethane, epoxy, and silicon. The first layer 204 may provide better structural stability, and better structural rigidity to the energy storage system 200. The first layer 204 retains the position of the one or more cells 102. The first layer 204 increases the durability of the one or more cells 102. The first layer 204 may increase reliability and structural rigidity. The first layer 204 is configured to reduce shock and vibration. Furthermore, the first layer 204 provides electrical insulation between the one or more cells 102, and the bottom casing. The first layer 204 spreads across the energy storage system 200.
The first layer 204 further provides increased durability to the energy storage system 200. The first layer 204 transfers heat from the one or more cells 102 to the bottom casing through the conduction process. The first layer 204 further resists movements of the one or more cells in the energy storage system 200. The first layer 204 is configured to reduce shock and vibration. The first layer faces an axial and circumferential surface of the one or more cells 102. The first layer 204 is configured to reduce the heat of the one or more cells 102 by transferring the heat to the plurality of fins. As used herein, a fin is defined as a surface that extends from an object to increase the rate of heat transfer to or from the environment by increasing convection. The plurality of fins is positioned on the outer walls of the top casing, and the bottom casing.
The bottom casing is filled with the first layer 204 to a third predetermined height. The third predetermined height depends on the heat generated by the one or more cells 102, or the energy storage system 200. The first layer 204 is poured to the third predetermined height of the bottom casing of the energy storage system 200, then the first cell holder 202, and the one or more cells 102 are dipped into the bottom casing of the energy storage system 200. The first cell holder 202 and the one or more cells 102 dipped into the bottom casing of the energy storage system200 in such a way that the first layer 204 contacts the axial surface of the one or more cells 102. In one embodiment, the first cell holder 202, and the one or more cells 102 dipped into the bottom casing of the energy storage system200 using a jig.
In one embodiment, the first cell holder 202, and the one or more cells 102 are placed into the bottom casing of the energy storage system200 then the first layer 204 is poured to the third predetermined height of the bottom casing of the energy storage system 200. The first cell holder 202 and the one or more cells 102 are placed into the bottom casing of the energy storage system200 in such a way that the first layer 204 contacts the axial surface of the one or more cells 102. In another embodiment, the first cell holder 202, and the one or more cells 102 are placed into the bottom casing of the energy storage system200 using the jig.
The first cell holder 202 is positioned on the bottom casing of the energy storage system 200. The first cell holder 202 provides a predetermined space between the one or more cells 102 and the bottom casing. The first cell holder 202 includes a plurality of cavities and is configured to hold the one or more cells 102 in a predetermined position. In one embodiment, the first cell holder 202 may include thermally conductive and electrically insulative material. In another embodiment, the first cell holder 202 may include a fire-retardant material. In yet another embodiment, the first cell holder 202 may include, but not limited to, a synthetic polymer-based material, a non-synthetic polymer-based material, and a thermo set plastic material.
In one embodiment, the one or more cells 102 may include, but not limited to, nickel cadmium, alkaline, nickel metal hydride (NIMH), lithium-ion, nickel hydrogen, lithium iron phosphate or lithium Ferro phosphate, nickel-zinc, electro-chemical cells, sodium ion, and the like. The first cell holder 202 is configured to provide the predetermined space between the bottom casing and the bottom surface of the one or more cells 102. In one embodiment, the predetermined space between the bottom casing and the bottom surface of the one or more cells 102 may depend on but not limited to, thermal behavior, structural stability, and electrical insulation of the one or more cells 102. In addition to that, the predetermined space provides insulation by the first layer 204.
Further, the first cell holder 202 and the first layer 204 are configured to increase the structural rigidity of the energy storage system 200. Once the first cell holder 202 and the one or more cells 102 are dipped/placed in the bottom casing, the second layer 206 is dispensed above the first layer 204. In one embodiment, the second layer 206 may include, but not limited to a thermal runaway propagation mitigation material, a high heat capacity, and an electrically insulative material. In one embodiment, the second layer 206 prevents cell thermal runaway/cell thermal propagation. In one embodiment, the thermal runaway propagation mitigation material, the high heat capacity, and the electrically insulative material may include, but not limited to, silicon foam, foam, polyurethane foam, polyurethane, polystyrene, silicon, and polyisocyanurate.
The second layer 206 may include, but not limited to, a low-density thermal conductive material, and an electrically insulating material. The second layer 206 may include a fire-retardant capacity. The second layer 206 is configured to prevent thermal run away propagation mitigation and reduce shock and vibration. The second layer 206 is configured to dissipate the heat of a radial surface of the one or more cells 102 by contacting the radial surface of the one or more cells 102. Furthermore, there is a difference between the first predetermined height of the one or more cells 102 and the second predetermined height of the thermally insulative structure 104.
The second predetermined height of the thermally insulative structure 104 is less than the first predetermined height of the one or more cells 102. In one embodiment, the second predetermined height of the thermally insulative structure 104 may be varied based on the predetermined height of the first layer 204.The second predetermined height of the thermally insulative structure 104 is designed in such a way the thermally insulative structure 104 covers the one or more cells 102 partially, not entirely. Since the thermally insulative structure 104 covers the one or more cells 102 partially, there is a predetermined radial surface of the one or more cells 102 which is not covered by the thermally insulative structure 104 to contact with the first layer 204. So, the heat that is emitted from the predetermined radial surface of the one or more cells 102 is absorbed by the first layer 204 to avoid the thermal trap of the one or more cells 102.
The top casing includes the thermally insulative material. The thermally insulative material is positioned in an inner wall of the top casing to avoid heat distribution from the one or more cells 102. In one embodiment, the thermally insulative material may include, but not limited to, phyllosilicate. The thermally insulative material may be positioned in the inner wall of the top casing using one or more joining processes. In one embodiment, the one or more joining processes include, but not limited to, an adhesive, tight fit and the like. In another embodiment, the thermally insulative material may be a coating, a sheet, a layer, and the like.
FIG. 3A, 3B, 3C & 3D illustrate a cross-sectional view of the energy storage system200 with one or more uncovered portions of the one or more cells 102 in the one or more layers, according to an embodiment herein.
The energy storage system200 includes the one or more cells 102. The one or more cells 102 include one or more uncovered portions in the one or more layers. In an embodiment, the one or more uncovered portions may include, but not limited to, a first uncovered portion 314, a second uncovered portion 316, and a third uncovered portion 318. In one embodiment, the one or more layers may include, but not limited to, the first layer 304, the second layer 306, and the third layer 308.
FIG. 3A illustrates a cross-sectional view of the energy storage system200 with the first layer 304, the second layer 306, the third layer 308, and a cooling system 312 according to an embodiment herein. The cross-sectional view discloses the one or more cells 102 are placed inside the energy storage system 200. The number of cells that are present in the energy storage system 200 may be varied based on the desired output rating of the energy storage system 200. The energy storage system200 includes a bottom casing (not shown in the figure), a first cell holder 302, a first layer 304, a second layer 306, a third layer 308, an interconnector 310, a cooling system 312,and a top casing (not shown in the figure).
The first layer 304 may include, but not limited to, resin, polymeric/non-polymeric material, polyurethane, epoxy, and silicon. The first layer 304 may provide better structural stability, and better structural rigidity to the energy storage system 200. The first layer 304 retains the position of the one or more cells 102. The first layer 304 increases the durability of the one or more cells 102. The first layer 304 may increase reliability and structural rigidity. The first layer 304 is configured to reduce shock and vibration. Furthermore, the first layer 304 provides electrical insulation between the one or more cells 102, and the bottom casing. The first layer 304 spreads across the energy storage system 200.
The first layer 304 further provides increased durability to the energy storage system 200. The first layer 304 transfers the heat from the one or more cells 102 to the bottom casing through the conduction process. The first layer 304 further resists movements of the one or more cells 102 in the energy storage system 200. The first layer 304 faces an axial and circum ferential surface of the one or more cells 102. The first layer 304 is configured to reduce the heat of the one or more cells 102 by transferring heat to the plurality of fins. As used herein, a fin is defined as a surface that extends from an object to increase the rate of heat transfer to or from the environment by increasing convection. The plurality of fins is positioned on the outer walls of the top casing, and the bottom casing.
The bottom casing is filled with the first layer 304 to a third predetermined height. The third predetermined height depends on the heat generated by the one or more cells 102, or the energy storage system 200.The first layer 304 is poured to the third predetermined height of the bottom casing of the energy storage system 200, then the first cell holder 302 and the one or more cells 102 are dipped into the bottom casing of the energy storage system200 in a manner that at least one of the first layer304faces an uncovered axial and circumferential surface of the one or more cells 102. The first cell holder 302 and the one or more cells 102 dipped into the bottom casing of the energy storage system200 in such a way that the first layer 304 contacts the axial surface of the one or more cells 102. In one embodiment, the first cell holder 302, and the one or more cells 102 dipped into the bottom casing of the energy storage system200 using a jig.
In one embodiment, the first cell holder 302, and the one or more cells 102 are placed into the bottom casing of the energy storage system200 then the first layer 304 is poured to the third predetermined height of the bottom casing of the energy storage system 200. The first cell holder 302 and the one or more cells 102 are placed into the bottom casing of the energy storage system200 in such a way that the first layer 304 contacts the axial surface of the one or more cells 102. In another embodiment, the first cell holder 302, and the one or more cells 102 are placed into the bottom casing of the energy storage system200 using the jig.
The first cell holder 302 is positioned on the bottom casing of the energy storage system 200. The first cell holder 302 provides a predetermined space between the one or more cells 102 and the bottom casing. The first cell holder 302 includes a plurality of cavities and is configured to hold the one or more cells 102 in a predetermined position. In one embodiment, the first cell holder 302 may include, but not limited to, thermally conductive and electrically insulative material. In another embodiment, the first cell holder 302 may include a fire-retardant material. In yet another embodiment, the first cell holder 302 may include, but not limited to, a synthetic polymer-based material, a non-synthetic polymer-based material, and a thermo set plastic material.
In one embodiment, the one or more cells 102 may include, but not limited to, nickel cadmium, alkaline, nickel metal hydride (NIMH), lithium-ion, nickel hydrogen, nickel-zinc, electro-chemical cells, and the like. The first cell holder 302 is configured to provide a predetermined space between the bottom casing and the bottom surface of the one or more cells 102. In one embodiment, the predetermined space between the bottom casing and the bottom surface of the one or more cells 102 may depend on but is not limited to, thermal behavior, structural stability, and electrical insulation of the one or more cells 102. In addition to that, the predetermined space provides insulation by the first layer 304. Further, the first cell holder 302 and the first layer 304 are configured to increase the structural rigidity of the energy storage system 200.
Once the first cell holder 302 and the one or more cells 102 are dipped/placed in the bottom casing, the second layer 306 is dispensed above the first layer 304. In one embodiment, the second layer 306 may include, but not limited to a thermal runaway propagation mitigation material, a high heat capacity, and an electrically insulative material. In one embodiment, the second layer 306 prevents cell thermal runaway/cell thermal propagation. In one embodiment, the thermal runaway propagation mitigation material may include, but not limited to, silicon foam, foam, polyurethane foam, polyurethane, polystyrene, silicon, and polyisocyanurate. The second layer 306 may include, but not limited to, a low-density thermal conductive material, and an electrically insulating material. The second layer 306 is configured to reduce shock and vibration. The second layer 306 may include a fire-retardant capacity. The second layer 306 is configured to prevent thermal runaway propagation mitigation and reduce shock and vibration.
The third layer 308 is dispensed above the second layer 306.In one embodiment, the third layer 308 may include, but not limited to, silicon, foam, polyurethane, polystyrene, and polyisocyanurate. The first layer 304 is configured to dissipate the heat of a radial surface of the one or more cells 102 by contacting the radial surface of the one or more cells 102. Furthermore, there is a difference between the first predetermined height of the one or more cells 102 and the second predetermined height of the thermally insulative structure 104. The second predetermined height of the thermally insulative structure 104 is less than the first predetermined height of the one or more cells 102.
In one embodiment, the second predetermined height of the thermally insulative structure 104 may be varied based on the predetermined height of the first layer 304. The predetermined height of the thermally insulative structure 104 is designed in such a way the thermally insulative structure 104 covers the one or more cells 102 partially, not entirely. Since the thermally insulative structure 104 covers the one or more cells 102 partially, there is a predetermined radial surface of the one or more cells 102 which is not covered by the thermally insulative structure 104 to contact with the first layer 304. So, the heat that is emitted from the predetermined radial surface of the one or more cells 102 is absorbed by the first layer 304 to avoid the thermal trap of the one or more cells 102.
The top casing includes a thermally insulative material. The thermally insulative material is positioned in an inner wall of the top casing to avoid heat distribution from the one or more cells 102. In one embodiment, the thermally insulative material may include, but not limited to, phyllosilicate. The thermally insulative material may be positioned in an inner wall of the top casing using one or more joining processes. In one embodiment, the one or more joining processes include, but not limited to, an adhesive, tight fit and the like. In another embodiment, the thermally insulative material may be a coating, a sheet, a layer, and the like.
The energy storage system200 further includes a cooling system 312. In one embodiment, the cooling system 312 includes, but not limited to, a liquid cooling system, or a gas cooling system. In another embodiment, the cooling system 312 is a layer. The layer includes a thermal interface material. In one embodiment, the thermal interface material may include, but not limited to, a thermal pad, a thermal paste, a gap pad, thermal grease, silicon, thermal gap filler, one or more phase-changing materials, and the like.
The cooling system 312 is positioned on a top portion of the interconnector 310. In one embodiment, the interconnector 310 may include, but not limited to, a PCB (Printed Circuit Board), a current collector, and the like. The interconnector 310 will be positioned between the third layer 308 and the cooling system 312 when the energy storage system200 includes the first layer 304, the second layer 306, and the third layer 308 (as shown in Figure 3). In one embodiment, the interconnector 310 will be positioned between the second layer 306 and the cooling system 312 when the energy storage system200 includes the first layer 304, and the second layer 306 (as shown in Figure3).
FIG. 3B illustrates a cross-sectional view of the energy storage system200 with the first uncovered portion 314, and the second uncovered portion 316 of the one or more cells 102 in the first layer 304 and the second layer 306, according to an embodiment herein.
The bottom casing is filled with the first layer 304 to the third predetermined height. The third predetermined height depends on the heat generated by the one or more cells 102, or the energy storage system 200. The first layer 304 is poured to the third predetermined height of the bottom casing of the energy storage system 200, then the first cell holder 302 and the one or more cells 102 are dipped into the bottom casing of the energy storage system 200. Once the first cell holder 302 and the one or more cells 102 are dipped/placed in the bottom casing, the second layer 306 is dispensed above the first layer 304. In one embodiment, the first layer 304 may include, but not limited to, resin, polymeric/non-polymeric material, polyurethane, epoxy, and silicon. In one embodiment, the second layer 306 may include, but not limited to a thermal runaway propagation mitigation material, a high heat capacity, and an electrically insulative material. In one embodiment, the second layer 306 prevents cell thermal runaway/cell thermal propagation. In one embodiment, the thermal runaway propagation mitigation material, the high heat capacity, and the electrically insulative material may include, but not limited to, silicon foam, foam, polyurethane foam, polyurethane, polystyrene, silicon, and polyisocyanurate.
The second layer 306 may include, but not limited to, a low-density thermal conductive material, and an electrically insulating material. The second layer 306 may include a fire-retardant capacity. The second layer 306 is configured to prevent thermal runaway propagation mitigation and reduce shock and vibration. The second layer 306 is configured to dissipate the heat of a radial surface of the one or more cells 102 by contacting the radial surface of the one or more cells 102. Furthermore, there is a difference between the first predetermined height of the one or more cells 102 and the second predetermined height of the thermally insulative structure 104.
The second predetermined height of the thermally insulative structure 104 is less than the first predetermined height of the one or more cells 102. In one embodiment, the second predetermined height of the thermally insulative structure 104 may be varied based on the predetermined height of the first layer 304. The second predetermined height of the thermally insulative structure 104 is designed in such a way the thermally insulative structure 104 covers the one or more cells 102 partially, not entirely. Since the thermally insulative structure 104 covers the one or more cells 102 partially, there is a predetermined radial surface of the one or more cells 102 which is not covered by the thermally insulative structure 104 to contact with the first layer 304. So, the heat that is emitted from the predetermined radial surface of the one or more cells 102 is absorbed by the first layer 304 to avoid the thermal trap of the one or more cells 102.
The second predetermined height of the thermally insulative structure 104 is constructed in a manner that the thermally insulative structure 104 covers the one or more cells 102 partially. In one embodiment, the first layer 304 faces the uncovered axial and circumferential surface of the one or more cells 102 to dissipate the heat. In another embodiment, the second layer 306 faces the uncovered axial and circumferential surface of the one or more cells 102 to dissipate the heat. In yet another embodiment, the first layer 304 and the second layer 306are face the uncovered axial and circumferential surface of the one or more cells 102 to dissipate the heat.
The first cell holder 302 and the one or more cells 102 are dipped into the bottom casing of the energy storage system200 in a manner that at least one of the first layer 304, and the second layer 306 faces the first and second uncovered portions 314, 316 of the axial and circumferential surface of the one or more cells 102. In an embodiment, the first layer 304 faces the first uncovered portion 314 of the axial and circumferential surface of the one or more cells 102. In one embodiment, the second layer 306 faces the second uncovered portion 316 of the axial and circumferential surface of the one or more cells 102. In another embodiment, the second uncovered portion 316 of the second layer 306 may be varied depending on the width of the second layer 306. In yet another embodiment, the second layer 306 may include one or more uncovered portions.
FIG. 3C illustrates a cross-sectional view of the energy storage system200 with the first uncovered portion 314 and the third uncovered portion 318 of the one or more cells 102in the first layer 304, and the third layer 308, according to an embodiment herein.
The bottom casing is filled with the first layer 304 to the third predetermined height. The third predetermined height depends on the heat generated by the one or more cells 102, or the energy storage system 200.The first layer 304 is poured to the third predetermined height of the bottom casing of the energy storage system 200. Once the first cell holder 302 and the one or more cells 102 are dipped/placed in the bottom casing, the second layer 306 is dispensed above the first layer 304. In one embodiment, the first layer 304 may include, but not limited to, resin, polymeric/non-polymeric material, polyurethane, epoxy, and silicon. The third layer 308 is dispensed above the second layer 306. In one embodiment, the third layer 308 may include, but not limited to, silicon, foam, polyurethane, polystyrene, and polyisocyanurate. The first layer 304 is configured to dissipate the heat of a radial surface of the one or more cells 102 by contacting the radial surface of the one or more cells 102.
In one embodiment, the first layer 304, and the third layer 308 face the first and third uncovered portions of the axial and circumferential surface of the one or more cells 102. In an embodiment, the first layer 304 faces the first uncovered portion 314 of the axial and circumferential surface of the one or more cells 102. In one embodiment, the third layer 308 faces the third uncovered portion 318 of the axial and circumferential surface of the one or more cells 102. In another embodiment, the third uncovered portion 318 of the third layer 308 may be varied depending on the width of the third layer 308. In yet another embodiment, the third layer 308 may include at least one or more uncovered portions.
FIG. 3D illustrates a cross-sectional view of the energy storage system200 with the first uncovered portion 314, the second uncovered portion 316, and the third uncovered portion 318 of the one or more cells 102 in the first layer 304, the second layer 306, and the third layer 308, according to an embodiment herein.
The bottom casing is filled with the first layer 304 to the third predetermined height. The third predetermined height depends on the heat generated by the one or more cells 102, or the energy storage system 200. The first layer 304 is poured to the third predetermined height of the bottom casing of the energy storage system 200. Once the first cell holder 302 and the one or more cells 102 are dipped/placed in the bottom casing, the second layer 306 is dispensed above the first layer 304. The third layer 308 is dispensed above the second layer 306. In one embodiment, the first layer 304 may include, but not limited to, resin, polymeric/non-polymeric material, polyurethane, epoxy, and silicon. In one embodiment, the second layer 306 prevents cell thermal runaway/cell thermal propagation. In another embodiment, the thermal runaway propagation mitigation material may include, but not limited to, silicon foam, foam, polyurethane foam, polyurethane, polystyrene, silicon, and polyisocyanurate. In one embodiment, the third layer 308 may include, but not limited to, silicon, foam, polyurethane, polystyrene, and polyisocyanurate.
In one embodiment, the first layer 304, the second layer 306,and the third layer 308 face the first uncovered portion 314, the second uncovered portion 316, and the third uncovered portion318 of the axial and circumferential surface of the one or more cells 102. In an embodiment, the first layer 304 faces the first uncovered portion 314 of the axial and circumferential surface of the one or more cells 102. In one embodiment, the second layer 306 faces the second uncovered portion 316 of the axial and circumferential surface of the one or more cells 102. In another embodiment, the second uncovered portion 316 of the second layer 306 may be varied depending on the width of the second layer 306. In yet another embodiment, the second layer 306 may include one or more uncovered portions. In one embodiment, the third layer 308 faces the third uncovered portion 318 of the axial and circumferential surface of the one or more cells 102. In another embodiment, the third uncovered portion 318 of the third layer 308 may be varied depending on the width of the third layer 308. In yet another embodiment, the third layer 308 may include one or more uncovered portions.
FIG. 4 is a flow diagram illustrating a method 400 of thermal management and thermal runaway propagation mitigation in an energy storage system 200. At step 402, placing the one or more cells 102 on a bottom casing of the energy storage system 200. The one or more cells 102 include a first predetermined height. In one embodiment, the first predetermined height may be varied based on an application in which the one or more cells 102 are used. Each cell of the one or more cells 102 includes a covered portion that is covered by a thermally insulative structure 104 and one or more uncovered portions that are not covered by the thermally insulative structure 104. The thermally insulative structure 104 is positioned around the one or more cells 102 and is configured to cover a circumferential surface of the one or more cells 102 partially to avoid heat distribution to the one or more cells 102. The one or more cells 102 will be placed inside the energy storage system 200. The number of cells that are present in the energy storage system 200 may be varied based on the desired output rating of the energy storage system 200.
At step 404, covering a circumferential surface of the one or more cells 102 partially to avoid heat distribution to the one or more cells 102 by positioning the thermally insulative structure 104.The thermally insulative structure 104 includes a second predetermined height. In one embodiment, the first predetermined height of the one or more cells 102 is higher than the second predetermined height of the thermally insulative structure 104.
The thermally insulative structure 104 includes a second predetermined height. In one embodiment, the second predetermined height of the thermally insulative structure 104 may be varied based on the first predetermined height of the one or more cells 102. In another embodiment, the first predetermined height of the one or more cells 102 will be higher than the second predetermined height of the thermally insulative structure 104. In another embodiment, the thermally insulative structure 104 may be a coating, a sheet, a layer, a block, and the like. The thermally insulative structure 104 is positioned around the one or more cells 102 to avoid heat distribution to the one or more cells 102 by using one or more joining processes.
In one embodiment, the one or more joining processes may be an adhesive, tight fit, and the like. In one embodiment, the thermally insulative structure 104 may be a less dense material with high specific heat. In an embodiment, the less dense material includes polyethylene foam, foam, and polyurethane foam. In one embodiment, the thermally insulative structure 104 may include, but not limited to, phyllosilicate. The thermally insulative structure 104 includes thermally insulative, and electrically insulative properties.
At step 406, pouring a first layer 204 into the bottom casing to a third predetermined height. In an embodiment, the third predator mined height depends on heat generated by the one or more cells 102, or the energy storage system 200. The first layer 204 is poured to the third predetermined height of the bottom casing of the energy storage system 200, then the first cell holder 202 and the one or more cells 102 are dipped into the bottom casing of the energy storage system200 in a manner that at least one of the first layer 204 faces an uncovered axial and circumferential surface of the one or more cells 102. The first cell holder 202 and the one or more cells 102 dipped into the bottom casing of the energy storage system200 in such a way that the first layer 204 contacts the axial surface of the one or more cells 102.In one embodiment, the first cell holder 202, and the one or more cells 102 dipped into the bottom casing of the energy storage system200 using a jig.
In one embodiment, the first cell holder 202, and the one or more cells 102 are placed into the bottom casing of the energy storage system200 then the first layer 204 is poured to the third predetermined height of the bottom casing of the energy storage system 200. The first cell holder 202 and the one or more cells 102 are placed into the bottom casing of the energy storage system200 in such a way that the first layer 204 contacts the axial surface of the one or more cells 102. In another embodiment, the first cell holder 202, and the one or more cells 102 are placed into the bottom casing of the energy storage system200 using the jig.
The first cell holder 202 is positioned on the bottom casing of the energy storage system 200. The first cell holder 202 provides a predetermined space between the one or more cells 102 and the bottom casing. The first cell holder 202 includes a plurality of cavities and is configured to hold the one or more cells 102 in a predetermined position. In one embodiment, the first cell holder 202 is thermally conductive and electrically insulative material. In another embodiment, the first cell holder 202 may include a fire-retardant material. In yet another embodiment, the first cell holder 202 may include, but not limited to, a synthetic polymer-based material, a non-synthetic polymer-based material, and a thermo set plastic material.
At step 408, dipping the first cell holder 202, and the one or more cells 102 into the bottom casing of the energy storage system200 using the jig. The first cell holder 202, and the one or more cells 102 are dipped into the bottom casing of the energy storage system200 in a manner that at least one of the first layer 204, the second layer 206, and the third layer 308 faces an uncovered axial and circumferential surface of the one or more cells 102. In one embodiment, the first layer 304 may include, but not limited to, resin, polymeric/non-polymeric material, polyurethane, epoxy, and silicon. In one embodiment, the second layer 306 prevents cell thermal runaway/cell thermal propagation. In another embodiment, the thermal runaway propagation mitigation material may include, but not limited to, silicon foam, foam, polyurethane foam, polyurethane, polystyrene, silicon, and polyisocyanurate. In one embodiment, the third layer 308 may include, but not limited to, silicon, foam, polyurethane, polystyrene, and polyisocyanurate.
In one embodiment, the first layer 304, the second layer 306, and the third layer 308 face the first uncovered portion 314, the second uncovered portion 316, and the third uncovered portion318 of the axial and circumferential surface of the one or more cells 102. In an embodiment, the first layer 304 faces the first uncovered portion 314 of the axial and circumferential surface of the one or more cells 102. In one embodiment, the second layer 306 faces the second uncovered portion 316 of the axial and circumferential surface of the one or more cells 102. In another embodiment, the second uncovered portion 316 of the second layer 306 may be varied depending on the width of the second layer 306. In yet another embodiment, the second layer 306 may include one or more uncovered portions. In one embodiment, the third layer 308 faces the third uncovered portion 318 of the axial and circumferential surface of the one or more cells 102. In another embodiment, the third uncovered portion 318 of the third layer 308 may be varied depending on the width of the third layer 308. In yet another embodiment, the third layer 308 may include one or more uncovered portions.
The energy storage system200 further includes a cooling system 312. In one embodiment, the cooling system 312 includes, but not limited to, a liquid cooling system, or a gas cooling system. In another embodiment, the cooling system 312 is a layer. The layer includes thermal interface material. In one embodiment, the thermal interface material may include, but not limited to, a thermal pad, a thermal paste, a gap pad, thermal grease, silicon, thermal gap filler, one or more phase-changing materials, and the like.
The cooling system 312 is positioned on a top portion of an interconnector 310. In one embodiment, the interconnector 310 may include, but not limited to, a PCB (Printed Circuit Board), a current collector, and the like. The interconnector 310 will be positioned between the third layer 308 and the cooling system 312 when the energy storage system200 includes the first layer 304, the second layer 306, and the third layer 308. In one embodiment, the interconnector 310 will be positioned between the second layer 306 and the cooling system 312 when the energy storage system200 includes the first layer 304, the second layer 306, and the third layer 308.
Improvements and modifications may be incorporated herein without deviating from the scope of the invention. The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.

LIST OF REFERENCE NUMERALS
102: One or more cells
104: Thermally insulative structure
200: Energy storage system
202, 302: First cell holder
204, 304: First layer
206, 306: Second layer
308: Third layer
310: Interconnector
312: Cooling system
314: First uncovered portion
316: Second uncovered portion
318: Third uncovered portion
,CLAIMS:1. An energy storage system (200) for thermal management and thermal runaway propagation mitigation, comprising: one or more cells (102) are placed on a bottom casing of the energy storage system (200), wherein the one or more cells (102) comprise a first predetermined height; a thermally insulative structure (104) is positioned around the one or more cells (102) and is configured to cover a circumferential surface of the one or more cells (102) partially to avoid heat distribution to the one or more cells (102), wherein the thermally insulative structure (104) comprises a second predetermined height; a first layer (204) faces an axial and circumferential surface of the one or more cells (102), wherein the first layer (204) is configured to reduce heat of the one or more cells (102) by transferring the heat to the plurality of fins, wherein the first layer (204) is configured to resist movements of the one or more cells (102), wherein the first layer (204) is filled inside the bottom casing to a third predetermined height, wherein the third predetermined height depends on the heat generated by the one or more cells (102), or the energy storage system (200); and a second layer (206) is configured to prevent thermal runaway propagation mitigation and reduce shock and vibration, wherein the second layer (206) faces the circumferential surface of the one or more cells (102) to dissipate the heat of the one or more cells (102).

2. The energy storage system (200) as claimed in claim 1, wherein the thermally insulative structure (104) is a less dense material, wherein the less dense material comprises polyethylene foam, foam, and polyurethane foam.

3. The energy storage system (200) as claimed in claim 1, wherein the thermally insulative structure (104) comprises a phyllosilicate.

4. The energy storage system (200) as claimed in claim 1, wherein the energy storage system (200) further comprises one or more cell holders.

5. The energy storage system (200) as claimed in claim 1, wherein the first layer (204) comprises resin, polymeric/non-polymeric material, polyurethane, epoxy, and silicon.

6. The energy storage system (200) as claimed in claim 1, wherein the second layer (206) comprises a thermal runaway propagation mitigation material, a high heat capacity, and an electrically insulative material, wherein the thermal runaway propagation mitigation material, the high heat capacity, and the electrically insulative material comprises silicon foam, foam, polyurethane foam, polyurethane, polystyrene, silicon, and polyisocyanurate.

7. The energy storage system (200) as claimed in claim 1, wherein the first predetermined height of the one or more cells (102) is higher than the second predetermined height of the thermally insulative structure (104).

8. The energy storage system (200) as claimed in claim1, wherein each cell of the one or more cells (102) comprises a covered portion that is covered by the thermally insulative structure (104) and one or more uncovered portions that are not covered by the thermally insulative structure (104).

9. The energy storage system (200) as claimed in claim 1, wherein the second predetermined height of the thermally insulative structure (104) is constructed in a manner that the thermally insulative structure (104) covers the one or more cells (102) partially, wherein at least one of the first layer (204) and the second layer (206) are face uncovered axial and circumferential surface of the one or more cells (102) to dissipate heat.

10. The energy storage system (200) as claimed in any one of the claims above wherein; the energy storage system (200) further comprises a third layer(308), wherein the third layer (308) is dispensed above the second layer (306), wherein the third layer (308)comprises silicon, foam, polyurethane, polystyrene, and polyisocyanurate.

11. A method (400) of thermal management and thermal runaway propagation mitigation, comprising: placing one or more cells (102) on a bottom casing of the energy storage system (200), wherein the one or more cells (102) comprise a first predetermined height; covering, by positioning the thermally insulative structure (104), a circumferential surface of the one or more cells (102) partially to avoid heat distribution to the one or more cells, wherein the thermally insulative structure (104) comprises a second predetermined height, wherein the first predetermined height of the one or more cells (102) is higher than the second predetermined height of the thermally insulative structure (104); pouring a first layer (204) into a bottom casing to a third predetermined height, wherein the third predetermined height depends on heat generated by the one or more cells (102) or the energy storage system (200); and dipping, using a jig, a first cell holder (202), and the one or more cells (102) into the bottom casing of the energy storage system(200) in a manner that at least one of the first layer (204) and the second layer (206) faces an uncovered axial and circumferential surface of the one or more cells (102).


12. A method (400) of thermal management and thermal runaway propagation mitigation, comprising: placing one or more cells (102) on a bottom casing of the energy storage system (200), wherein the one or more cells (102) comprise a first predetermined height; covering, by positioning the thermally insulative structure (104), a circumferential surface of the one or more cells (102) partially to avoid heat distribution to the one or more cells, wherein the thermally insulative structure (104) comprises a second predetermined height, wherein the first predetermined height of the one or more cells (102) is higher than the second predetermined height of the thermally insulative structure (104); placing the first cell holder (202), and the one or more cells (102) into the bottom casing of the energy storage system (200); and pouring the first layer (204) to the predetermined height of the bottom casing of the energy storage system (200).

13. Method (400) as claimed in claim 11orclaim 12, wherein the method (400) comprises: placing a cooling system (312) on top of an interconnector (310) to absorb the heat of the energy storage system (200), wherein the interconnector (310) is positioned between the second layer (306) and the cooling system (312).

14. The method (400) as claimed in claim 11orclaim 12, wherein the method (400) comprises: dipping, using a jig, a first cell holder (302), and the one or more cells (102) into the bottom casing of the energy storage system (200) in a manner that at least one of the first layer (304), the second layer (306) and the third layer (308) faces an uncovered axial and circumferential surface of the one or more cells (102).