4 Thermal Management Design & Safety

Estimate heat generation under different operating conditions. Choose a cooling/heating method: air (passive/forced), liquid (direct/indirect), PCMs, or refrigerant-based. Design flow paths, manifolds, and components (fans, pumps, radiators), and include heating for cold climates if needed.

Select materials (e.g., mica, ceramic fiber, PCMs) to slow or block thermal runaway between cells. Design their placement between or around cell groups. Consider thermal conductivity, heat capacity, flame resistance, and manufacturability for effective integration into the module.

Understand how the selected cells vent (e.g., score lines, vent ports, seam failure). Design the enclosure to direct gases and ejecta safely away from critical components. Ensure vent paths are clear and sized for expected gas flow, and assess impacts on nearby parts.