Hazard mitigation within a battery pack using metal-air cells

• US 8,445,126 B2
• Filed: 02/14/2011
• Issued: 05/21/2013
• Est. Priority Date: 08/10/2010
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Hermann, Weston Arthur
• Primary Examiner(s): Ruddock, Ula C
• Assistant Examiner(s): CHERNOW, FRANK A
• Application Number:
  US13/027,059
• Publication Number:
  US 20120040212A1
• Time in Patent Office: 827 Days
• Field of Search: 429/62, 429/9, 429/61
• US Class Current: 429/9
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/02 to electric heating circuits
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/14 Acceleration
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/662 Temperature
• CPC Class Codes: B60L 2250/12 by confirmation, e.g. of the input
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0061 relating to electrical machines
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• CPC Class Codes: B60L 58/16 responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
• CPC Class Codes: B60L 58/20 : having different nominal voltages
• CPC Class Codes: B60L 58/21 : having the same nominal voltage
• CPC Class Codes: B60L 58/24 : for controlling the temperature of batteries
• CPC Class Codes: B60L 58/26 : by cooling
• CPC Class Codes: B60L 58/27 : by heating
• CPC Class Codes: H01M 10/0525 : Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/30 : Nickel accumulators H01M10/34 takes precedence
• CPC Class Codes: H01M 10/32 : Silver accumulators H01M10/34 takes precedence
• CPC Class Codes: H01M 10/345 : Gastight metal hydride accumulators
• CPC Class Codes: H01M 10/443 : in response to temperature
• CPC Class Codes: H01M 10/486 : for measuring temperature
• CPC Class Codes: H01M 10/613 : Cooling or keeping cold
• CPC Class Codes: H01M 10/633 : characterised by algorithms, flow charts, software details or the like
• CPC Class Codes: H01M 10/6561 : Gases
• CPC Class Codes: H01M 10/6567 : Liquids
• CPC Class Codes: H01M 12/06 : with one metallic and one gaseous electrode
• CPC Class Codes: H01M 12/08 : composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
• CPC Class Codes: H01M 16/00 : Structural combinations of different types of electrochemical generators
• CPC Class Codes: H01M 16/006 : of fuel cells with rechargeable batteries
• CPC Class Codes: H01M 2200/10 : Temperature sensitive devices
• CPC Class Codes: H01M 2200/20 : Pressure-sensitive devices
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/204 : Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/253 : adapted for specific cells, e.g. electrochemical cells operating at high temperature
• CPC Class Codes: H01M 50/317 : Re-sealable arrangements
• CPC Class Codes: H01M 50/375 : Vent means sensitive to or responsive to temperature
• CPC Class Codes: H02J 7/0029 : with safety or protection devices or circuits
• CPC Class Codes: H02J 7/14 : for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y02T 90/167 : Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y04S 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

A system and method for mitigating the effects of a thermal event within a battery pack is provided in which the hot gas and material generated during the thermal runaway of at least one non-metal-air cell of a plurality of non-metal-air cells is directed through one or more metal-air cells, the metal-air cells absorbing at least a portion of the thermal energy generated during the event before it is released to the ambient environment. As a result, the risks to vehicle passengers, bystanders, first responders and property are limited.

Claims

1. A battery pack with an integrated hazard mitigation system, comprising:

a battery pack enclosure;

a plurality of metal-air cells contained within said battery pack enclosure;

a plurality of non-metal-air cells contained within said battery pack enclosure;

a first air inlet providing a first air flow pathway into and out of said battery pack enclosure, wherein air entering said first air inlet flows through said plurality of non-metal air cells prior to flowing through said plurality of metal-air cells;

a second air inlet providing a second air flow pathway into and out of said battery pack enclosure, wherein air entering said second air inlet flows through said plurality of metal-air cells without first flowing through said plurality of non-metal air cells;

a first valve coupled to said first air inlet, wherein said first valve controls air flow through said first air inlet;

at least one temperature sensor within said battery pack enclosure;

a system controller coupled to said first valve and to said at least one temperature sensor, wherein said system controller is programmed to determine if a temperature monitored by said at least one temperature sensor is indicative of at least one of said plurality of non-metal-air cells entering into thermal runaway, and wherein if said temperature monitored by said at least one temperature sensor is indicative of at least one of said plurality of non-metal-air cells entering into thermal runaway said system controller is further programmed to close said first valve, wherein closing said first valve closes said first air inlet and forces effluent generated during said thermal runaway of at least one of said plurality of non-metal-air cells to pass through said plurality of metal-air cells before being expelled through said second air inlet.

2. The battery pack of claim 1, wherein said system controller is programmed to compare said temperature to a preset temperature, wherein said preset temperature is indicative of at least one of said plurality of non-metal-air cells entering into thermal runaway.

3. The hazard mitigation system of claim 1, further comprising a high pressure relief valve coupled to said battery pack enclosure.

4. The hazard mitigation system of claim 1, further comprising a second valve coupled to said second air inlet, wherein said second valve controls air flow through said second air inlet, and wherein said system controller is further programmed to temporarily close said second valve when said temperature monitored by said at least one temperature sensor is indicative of at least one of said plurality of non-metal-air cells entering into thermal runaway.