Multi-level passive-active thermal control for battery thermal runaway prevention and suppression in electric vehicles

Resolving the contradiction between heat-dissipation during normal operation and thermal-insulation after thermal runaway (TR) is highly desirable for battery thermal safety system but remains challenges. Herein, a multi-leveled thermal control strategy, i.e., passive cooling - active cooling - passive suppression - active suppression, has been proposed for TR prevention-suppression of the battery packs. The system is primarily designed by modular composite phase change material (CPCM), liquid cooling (LC) plates and aerogel plates (APs). Firstly, the passive cooling CPCM coordinated with active LC enables a suitable working temperature, low temperature gradient and low energy consumption of the battery pack under variable environments. Secondly, the modular design of the battery pack couples with the passive thermal-insulation effect of APs, successfully preventing TR from propagating to other modules. Thirdly, APs work synergistically with dynamic LC, greatly enhancing the directional heat-dissipation, and consequently, the TR propagation can be suppressed to the lowest level. By the flexible dynamic flow rate adjustment, the TR of large-scaled battery packs with different configurations of 4S12P, 6S8P, 8S6P and 12S4P can be successfully suppressed in the initially-triggered cell.