Design a thermal management strategy to prevent thermal runaway propagation in a 100 kWh EV battery pack.
Answer
Comprehensive strategy includes: Cell-level protection (ceramic-coated separators, PTC thermistors, CID vents), Module design with fire-resistant barriers between cell groups (mica sheets, intumescent materials expanding at ~150°C), Active cooling maintaining cells at 25-35°C with redundant pumps and multiple cooling circuits, Early detection via distributed temperature sensing (fiber optic or NTC thermistors every 2-3 cells) with ML-based anomaly detection, Controlled venting through pressure relief directing gases to safe exhaust pathways away from passengers, Passive propagation delay using phase change materials (paraffin with 200 J/g latent heat) providing 3-5 minute buffer, and BMS integration shutting down affected modules while maintaining others. Testing per UNECE R100 validates 5-minute no-propagation requirement.
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