Expansion type battery charging cover shell

Abstract

The invention provides a fireproof housing which is used for placing a battery during charging. The enclosure comprises: an outer shell made entirely or mainly of a material coated or impregnated with a solution comprising an expanding material; and the internal bracket is used for preventing the housing from being deformed in the use process. The housing is formed with discrete openings through which the power transmission cable can pass, and the housing further comprises at least one vent which is closed by rapid expansion of the expansion material in the event of overheating.

Description

Technical Field

[0001] This invention relates to a fireproof cover for a battery cell in a battery-powered vehicle. Background Technology

[0002] In recent years, personal urban transportation (especially in cities) has increasingly been achieved through battery-powered vehicles, such as (but not limited to) e-scooters, e-bikes, electric motorcycles, electric tricycles, electric balance bikes, electric skateboards, and electric unicycles.

[0003] To some extent, the increase in these modes of transportation is due to advancements in battery technology. Historically, lead-acid batteries have been widely used due to their low cost and ease of operation; the electricity in lead-acid batteries is generated by the chemical reaction between lead, lead dioxide, and sulfuric acid.

[0004] Similarly, nickel-cadmium (NiCd) batteries have historically been popular; in particular, NiCd batteries offer stable output over a wide temperature range and exhibit tolerance to numerous charge-discharge cycles.

[0005] However, lead-acid batteries are heavy and bulky, and their energy density is lower compared to existing alternatives. Furthermore, nickel-cadmium batteries suffer from the "memory effect," meaning that if a battery is recharged before fully discharging all its stored energy, it "remembers" a smaller capacity, resulting in a gradual decrease in its energy storage capacity after each charge-discharge cycle. In addition, the heavy metals lead and cadmium in both lead-acid and nickel-cadmium batteries have a negative impact on the environment.

[0006] Recently, lithium-ion technology has provided high-energy-density batteries, enabling lightweight and compact energy storage solutions suitable for personal battery-powered vehicles. Electric vehicles using lithium-ion batteries (LiB), such as electric scooters, have a longer driving range compared to lead-acid and nickel-cadmium batteries. Furthermore, unlike nickel-cadmium batteries, lithium-ion batteries are not affected by the "memory effect."

[0007] Even considering the relatively high cost of lithium-ion batteries compared to lead-acid and nickel-cadmium batteries, their advantages such as high energy density, accessibility, low cost, long lifespan, and compact size have led to their widespread use in the electric vehicle market, especially in electric scooters and electric bicycles.

[0008] Despite the aforementioned advantages, lithium-ion batteries still pose a considerable fire risk. With the widespread adoption of lithium-ion batteries and the significant growth of the personal battery-powered transportation market, the London Fire Brigade (LFB) handled over 116 fires involving e-scooters and e-bikes in 2022. By autumn 2023, in London alone, lithium-ion battery fires related to electric vehicles had resulted in at least 3 deaths and 51 injuries.

[0009] Thermal runaway and fire problems in lithium-ion batteries are well known, primarily caused by electrical damage (overcharging / discharging), thermal damage (overheating), mechanical damage (penetration, crushing, or bending), and internal short circuits (ISC).

[0010] It is known that moving a lithium-ion battery from its original location to a charging position increases the risk of mechanical damage. Furthermore, lithium-ion batteries are often charged unattended, which increases the risk of electrical damage. Users may also charge lithium-ion batteries on unsuitable surfaces or in unsuitable locations (such as in spaces that isolate them), thus increasing the risk of thermal damage. Therefore, most household lithium-ion battery fires occur during charging, not during use.

[0011] GB2532933 teaches a temporary enclosure for housing a battery-powered motor vehicle (e.g., a motorized scooter) during charging. The temporary enclosure is self-supporting and includes a cover made of fire-resistant fabric supported on a frame. The enclosure includes a closable opening to allow the motor vehicle to enter and exit the enclosure, and includes means for connecting the vehicle's power supply to a power source. The fabric may include silicone-coated glass cloth with a fire resistance of at least 1200 degrees Celsius, polyurethane material with a fire resistance of at least 1100 degrees Celsius, or graphite cloth with a fire resistance of at least 1200 degrees Celsius. The frame may include an assembly of metal or plastic rods and clips. In addition to being fire-resistant, the fabric may also be waterproof.

[0012] GB2532933 effectively prevents the outbreak and spread of fires from rechargeable lithium-ion batteries placed inside motor vehicles. However, the devices taught in GB2532933 are not suitable for placing individually rechargeable lithium-ion batteries due to the lack of a base, ventilation issues, and the size limitations of temporary enclosures.

[0013] The purpose of this invention is to provide a housing for placing a lithium-ion battery during charging, and the housing isolates and protects the user from thermal runaway and fire hazards caused by the lithium-ion battery. Summary of the Invention

[0014] In one aspect, the present invention provides a fireproof enclosure for placing a battery during charging, the enclosure comprising: an outer shell made entirely or primarily of a material coated or impregnated with a solution containing an expanding material; an internal support that prevents the enclosure from deforming during use; wherein the outer shell is formed with discrete openings through which a power transmission cable can pass, and the outer shell further comprises at least one vent that is closed by rapid expansion of the expanding material in the event of overheating.

[0015] Preferably, the housing includes a front wall, a rear wall, and side walls covered by a lid, the lid being hinged to the rear wall.

[0016] Preferably, the internal support consists of support members located substantially at the upper inner edges of the front and side walls of the housing.

[0017] In a preferred embodiment, the support member comprises an elongated strip formed of stainless steel.

[0018] Preferably, the lid includes a side piece extending downward from the upper edge of the front wall and side wall of the outer casing.

[0019] Preferably, the Velcro (RTM) is located substantially on the upper outer edges of the front and side walls of the housing and on the opposite sides of the cover's edge.

[0020] Preferably, the housing includes a sealed thermoplastic tube containing a fire extinguishing gas or fluid that is released from the tube in the event of a fire inside the housing.

[0021] Preferably, the housing includes a base on which the corresponding battery unit is located. Attached Figure Description

[0022] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which:

[0023] Figure 1 and Figure 2 These are, respectively, a front view and a rear view of the battery charging housing according to the present invention;

[0024] Figure 3 yes Figure 1 and Figure 2 The side view of the enclosure shown; and

[0025] Figure 4 This is a perspective view of the casing shown in the aforementioned figure, with the lid open. Detailed Implementation

[0026] Figures 1 to 4The battery charging housing 10 shown is typically made of cloth or fabric or sheet material (hereinafter referred to as "cloth"), which is coated on one or both sides with a solution containing an expandable material to form a relatively robust structure. The cloth may be adhered to a rigid or semi-rigid backing plate (e.g., sheet material or similar sheet material).

[0027] The outer shell is typically made by simply sewing together pieces of coated fabric of appropriate size to form a body of appropriate shape and size, which includes a front wall 12, side walls 14, a rear wall 16 and a closable cover 18 formed by downwardly extending side walls 20 and a downwardly extending front wall 22.

[0028] The rear wall 16 of the enclosure includes a patch 34 comprising a plurality of vents 36 to aid in cooling the interior of the enclosure. The patch 34 includes a coating comprising a material that expands in the event of a fire. If a fire occurs inside the enclosure, the intumescent coating rapidly expands to close the openings, thereby inhibiting the spread of fire to surrounding areas. Similar patches may be located on the front and / or side walls of the enclosure.

[0029] like Figure 3 As shown, the lid is connected to the rear wall via a fold 24 in the material of the outer shell, which serves as a hinge.

[0030] Once completed, the assembled casing, including the stitching, will be coated with an additional coating of expandable material.

[0031] When the cover is closed, the downward-extending sidewall 20 of the cover 18 extends beyond the front wall and upper part of the sidewall of the housing to provide better protection.

[0032] Once the coating on the outer shell is complete, the shell can stand relatively independently.

[0033] Velcro 26 is attached to the outer surface of the sidewall 14 and to the inner surface of the overlapping sides 20, 22 of the cover 18 so that each housing can be closed after the battery cell is placed in the corresponding housing.

[0034] To ensure that the Velcro 26 is fully secured to the outer surface of the sidewall 14 and to the inner surfaces of the overlapping sides 20, 22 of the cover 18, the support member 38 is secured around the inner surfaces 42, 40 and 44 of the cover 10.

[0035] Specifically, the support member 38 is located at least substantially in the corresponding area that corresponds to the position of the Velcro 26, thereby preventing deformation of the front wall 12 and the side wall 14 and maintaining a structure consistent with the cover 18 and the overlapping sides 20 and 22.

[0036] Alternatively, the support member 38 may extend to support the entire frame of the fireproof enclosure 10, thereby acting as an internal support. Alternatively, as shown, the support member 38 may include an elongated strip that traverses at least three inner surfaces 42, 40, and 44 of the enclosure 10.

[0037] The slender strips can also be arranged to form a support; for example, but not limited to, the strips can be assembled into cross braces, corner posts, or beams.

[0038] The support member 38 can be in the form of a panel, which can be arranged as a partition insert or act as a double-wall component to support the housing 10.

[0039] The support member 38 may be formed of any suitable non-combustible or flame-retardant material, such as, but not limited to, stainless steel, mineral fiber, ceramic fiber, asbestos-free calcium silicate board, basalt fiber and phenolic foam.

[0040] The support member 38 can be fastened to the inner surfaces 42, 40 and 44 of the housing by any suitable non-flammable or flame-retardant fastening device, such as, but not limited to, stainless steel fasteners, ceramic fasteners, glass fiber nylon fasteners, PTFE (polytetrafluoroethylene) coated fasteners, silicone rubber fasteners, and brass fasteners.

[0041] Alternatively, the support member 38 can be fastened to the inner surfaces 42, 40 and 44 by any suitable high-temperature resistant adhesive, such as, but not limited to, epoxy adhesives, silicone adhesives, ceramic adhesives and polyimide adhesives.

[0042] The support member 38 ensures that the structure of the housing 10 will not fold onto the enclosed rechargeable battery cell and cause thermal runaway. In addition, the support member 38 ensures that the housing has sufficient sealing during use so that the housing maintains its structure during expansion in the event of thermal runaway, thereby facilitating the sealing of the space between the cover 18 and the housing body and suppressing flames.

[0043] from Figure 3 As can be seen, the material between the cover 18 and the rear wall 16 defines the hinge to help open and close the housing.

[0044] from Figure 3 It can also be seen that the front wall 22 of the housing is at least partially open along at least one of its sides to define an opening for entry of cables or other connecting devices from adjacent charging devices. Similarly, the upper end of the front wall 12 of the housing may be partially open to accommodate such cables.

[0045] In an alternative arrangement, the cover 18 can be separated from the sidewalls and front wall of the housing.

[0046] As described above, one or both sides of the cloth sheet constituting the cover are coated with a solution containing a sufficient amount of expanding material, which causes the casing to collapse and cover the battery contents inside the casing when a fire occurs inside the casing, thereby quickly or immediately covering and extinguishing the fire.

[0047] A gasket 34 is located in the rear wall 16 of the housing and forms vents 36 for heat dissipation from the interior of the housing during use. The gasket 34 is lined with and / or coated with a material that expands upon overheating. During normal use, these vents 36 prevent overheating of the interior of the housing. However, in the event of a fire, the coating of the expanding material will rapidly expand to close the vents.

[0048] In a preferred arrangement, each fireproof enclosure contains a sealed thermoplastic tube filled with extinguishing gas. In the event of a fire inside the enclosure, the sealed tube releases liquid, gas, or fluid to extinguish the fire within seconds.

Claims

1. A fire resistant enclosure for placing a battery while charging, the enclosure comprising: an outer shell, completely or predominantly made of a material coated or impregnated with a solution containing an intumescent material; an internal support that prevents the deformation of the enclosure during use; wherein the outer shell is formed with discrete openings through which power delivery cables can pass, and further comprises at least one vent that is closed by rapid expansion of the intumescent material upon overheating.

2. The enclosure of claim 1, wherein the outer shell comprises a front wall, a rear wall and side walls covered by a lid, the lid being hingedly connected to the rear wall.

3. The enclosure of claim 1, wherein the internal support is comprised of support members located substantially at the upper inner edges of the front wall and side walls of the outer shell.

4. The enclosure of claim 3, wherein the support members comprise elongated strips formed of stainless steel.

5. The enclosure of any one of claims 2 to 4, wherein the lid comprises a rim extending downwardly from the upper edges of the front wall and side walls of the outer shell.

6. The enclosure of claim 5, wherein Velcro is located substantially at the opposite faces of the upper outer edges of the front wall and side walls of the outer shell and the rim of the lid.

7. The enclosure of any one of claims 2 to 4, wherein the outer shell comprises a sealed thermoplastic tube containing a fire suppressant fluid that is released from the sealed thermoplastic tube when a fire occurs within the outer shell.

8. The enclosure of any one of claims 2 to 4, wherein the outer shell comprises a base on which the respective batteries are located.

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