Thermal runaway emergency processing system of power battery pack and working principle of thermal runaway emergency processing system

Abstract

The invention discloses a thermal runaway emergency treatment system for a power battery pack and a working principle of the thermal runaway emergency treatment system. The thermal runaway emergency treatment system comprises a sensing module, a control module, a quick separation executing mechanism and a multifunctional composite material releasing device, the sensing module is used for monitoring the temperature, voltage and smoke of the battery pack and a vehicle collision acceleration signal in real time; the control module is used for receiving and judging the signal and sending a trigger instruction when the signal reaches a preset danger threshold value; the quick separation executing mechanism is connected between the battery pack and the chassis of the vehicle body and is used for receiving the triggering instruction and instantly releasing mechanical and main electrical connection between the battery pack and the vehicle body so that the battery pack can fall off from the vehicle body; the multifunctional composite material release device is pre-arranged on the side of a battery pack and is used for automatically releasing and unfolding a composite material with high fire resistance, thermal expansion suffocation and phase change heat absorption characteristics after the battery pack falls off, so that the falling battery pack is completely coated with the composite material, and physical isolation, suffocation fire extinguishing and continuous cooling are realized.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle protection technology, specifically to a thermal runaway emergency response system for a power battery pack and its working principle. Background Technology

[0002] As the global automotive industry accelerates its transition to electrification, the number of new energy vehicles on the road is surging. However, the safety of power systems centered on high-energy-density lithium-ion batteries remains a major public concern and a primary challenge for the industry's development. Fires caused by battery thermal runaway are characterized by intense combustion, high temperatures, high re-ignition rates, and the production of toxic fumes, seriously threatening the lives of passengers. Currently, most battery packs are fixedly installed in the vehicle chassis, lacking proactive fire suppression measures. Existing in-vehicle battery fire suppression solutions often involve placing gaseous or liquid extinguishing agents such as perfluorohexanone inside the battery compartment. However, these solutions have significant shortcomings: firstly, the extinguishing agent is difficult to effectively penetrate within the sealed battery pack; secondly, even if the open flame is temporarily suppressed, the internal chemical reaction of the battery continues, making reignition highly likely; and finally, the fire source remains inside the vehicle, with high temperatures and toxic gases gradually infiltrating the passenger compartment. Therefore, there is an urgent need for a safety device that can actively and physically isolate the hazardous source (thermal runaway battery pack) from the passenger compartment and efficiently and persistently suppress fires. Summary of the Invention

[0003] The purpose of this invention is to design an emergency response system for thermal runaway of a power battery pack to solve the problems mentioned in the background art.

[0004] To achieve the above-mentioned technical effects, the present invention is implemented through the following technical solution: a thermal runaway emergency handling system for a power battery pack, comprising a sensing module, a central control unit, a rapid separation actuator, and a multifunctional composite material release device, characterized in that: each module is connected via a CAN bus or a dedicated cable; the signal input of the sensing module is sent to the central control unit, and the output of the central control unit controls the rapid separation actuator and the multifunctional composite material release device;

[0005] Furthermore, the sensing module includes temperature sensors, a battery management system, a smoke sensor, and a collision sensor installed in the vehicle body, all distributed within the battery pack. The central control unit has preset multi-level judgment logic: for example, when a single temperature sensor exceeds a threshold and continues to rise, an early warning is issued; when multiple temperature sensors exceed thresholds and are accompanied by smoke signals, or when the collision acceleration exceeds a specific value and the temperature is abnormal, the highest-level trigger command is immediately generated.

[0006] Furthermore, the rapid separation actuator includes a chassis mounting plate located at the bottom of the battery pack storage compartment, connecting screw holes located at the four corners of the chassis mounting plate and on the longitudinal beams of the vehicle chassis, bolts threaded into the connecting screw holes, bolt heads installed at the bottom of the bolts, a hollow cavity located in the middle of the bolts, explosives, a firing device, a firing pin and a firing pin port placed sequentially from bottom to top inside the hollow cavity, an excitation device installed at the upper end of the connecting screw holes and covering the bolts, and V-shaped fracture grooves located on both sides of the lower end of the bolts;

[0007] Furthermore, the multifunctional composite material release device includes a dedicated compartment located on the side of the battery pack, a composite material compression tank installed inside the dedicated compartment, a nozzle located at the bottom of the dedicated compartment, a delivery pipe connecting the output end of the composite material compression tank and the nozzle, a solenoid valve installed in the middle of the delivery pipe, and a wire connecting the solenoid valve and the central control unit.

[0008] Furthermore, the triggering device includes a protective cover installed on the upper end of the connecting screw hole and covering the bolt, an electromagnetic firing pin installed on the upper end of the protective cover, a blocking ring disposed in the middle of the protective cover, and a return spring connecting the electromagnetic firing pin and the blocking ring.

[0009] Furthermore, the electromagnetic firing pin includes a sliding block slidably mounted on the upper end of the protective cover, an electromagnet disposed on the outer ring of the sliding block, a firing pin mounted in the middle of the sliding block and adapted to the firing pin opening, an iron ring disposed on the upper surface of the blocking ring, and lead wires connecting the electromagnet and the central control unit.

[0010] Furthermore, the working principle of the rapid separation actuator is as follows:

[0011] S1, Electrical signal capture: When the vehicle monitoring system receives the battery thermal runaway signal, it sends a large instantaneous current to the lead wire;

[0012] S2. Electromagnetic thrust generation: The electromagnet on the excitation device generates a strong magnetic field, which instantly attracts the iron ring. At this time, the firing pin quickly strikes the firing pin.

[0013] S3. Activation of the firing device: The firing device is activated by the impact detonation of the firing pin, which further ignites the explosive.

[0014] S4. Brittle fracture separation: The explosive releases a large amount of high-pressure gas in a very short time. The pressure acts on the inner wall of the bolt, causing the weakest V-shaped fracture groove to undergo brittle fracture.

[0015] S5. Battery detachment: As the bolt head breaks, the battery pack loses its physical constraint and detaches naturally under gravity.

[0016] Furthermore, the working principle of the multifunctional composite material release device is as follows:

[0017] S1, Trigger Control Unit: The solenoid valve is set to open after receiving a signal from the central control unit;

[0018] S2. Composite material compression tank delivery: After the solenoid valve is opened, the composite material compression tank is connected to the nozzle. Under the action of high air pressure inside the composite material compression tank, the internal composite material flame retardant is sprayed onto the battery pack for fire extinguishing and flame retardant.

[0019] S3. Mechanical linkage triggering mechanism: The signal of bolt breakage is connected to the multi-functional composite material release device. Once triggered, the two devices work simultaneously to ensure that the spraying action and battery pack detachment are synchronized.

[0020] Another objective of this invention is to provide a working principle for a thermal runaway emergency response system for a power battery pack. The system's workflow comprises four stages: signal acquisition, logical judgment, action execution, and final protection. The specific steps are as follows:

[0021] S1. Signal Acquisition and Monitoring Phase: The system first monitors the battery pack status in real time using sensors in four dimensions:

[0022] Temperature sensor: monitors the thermal management status of the battery pack;

[0023] Collision sensors: monitor whether a vehicle has been involved in a physical collision;

[0024] Smoke sensor: Detects whether smoke is generated inside the battery pack in the early stages of thermal runaway;

[0025] Battery monitoring sensor: Monitors for abnormal electrical parameters such as voltage and current;

[0026] These four sets of sensors will transmit and summarize the collected data to the central control unit in real time.

[0027] S2, Logical Judgment Stage: The central control unit, as the core processing hub, analyzes and performs threshold comparisons on the received sensor signals.

[0028] Judgment Logic: The system determines whether the current state is extremely dangerous.

[0029] No (Safety / False Alarm): When the judgment result is "No", the system determines that no intervention is needed, the program execution stops, and the process directly enters the end state to avoid accidental operation.

[0030] Yes (Danger): When the judgment result is "Yes", it is confirmed as a dangerous situation, and the system immediately enters the trigger mode;

[0031] S3, Parallel Trigger Execution Phase: Once a dangerous situation is confirmed, the central control unit will simultaneously issue commands to trigger two subsystems in parallel:

[0032] Path A: Activate the rapid separation actuator to prepare for the physical separation of the battery pack from the vehicle body;

[0033] Path B: Activate the multi-functional composite material release device to prepare for the release of fire extinguishing or heat insulation materials;

[0034] S4. Action Interaction and Protection Phase: This is the core protection step of the system, involving two actions performed in tandem.

[0035] Battery pack detachment: The rapid separation mechanism activates, detaching the vehicle's power battery pack from the vehicle chassis and isolating it from potential hazards.

[0036] Covering functional materials: The release device sprays or covers a multifunctional composite material (liquid perfluorohexanone);

[0037] Two-way interaction: Covering occurs simultaneously with detachment, or the detachment action triggers the covering mechanism, ensuring that the battery is protected the instant it leaves the vehicle body;

[0038] S5. Final Stage: After the above actions, the battery is finally covered, achieving the goal of separating the hazardous battery from the vehicle and safely covering and sealing it; at this point, the entire safety protection process is complete.

[0039] The beneficial effects of this invention are:

[0040] 1) Actively isolate the source of danger: By quickly separating the thermal runaway battery pack from the vehicle body, the continuous damage to the passenger compartment by high temperature, flame and toxic gas is fundamentally avoided, and valuable time is gained for passenger escape and rescue.

[0041] 2) Highly efficient and long-lasting fire extinguishing: The fire is covered with a multifunctional composite material (liquid perfluorohexanone), which has the property of expanding when heated to quickly suffocate open flames. The phase change material and extinguishing agent contained therein can continuously absorb heat and inhibit internal chemical reactions, effectively preventing reignition.

[0042] 3) Intelligent and reliable response: Based on a decision-making mechanism of multi-sensor fusion, the false trigger rate is low, ensuring that it is activated only in real dangerous situations;

[0043] 4) Compact structure and easy integration: The separation mechanism and material release device can be adapted to the existing battery pack structure without major changes to the overall vehicle architecture. Attached Figure Description

[0044] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0045] Figure 1 This is an overall block diagram of the system described in this invention;

[0046] Figure 2 This is a schematic diagram of the installation position of the system described in this invention on the vehicle chassis;

[0047] Figure 3 This is a schematic diagram of the installation position of the system described in this invention in another direction on the vehicle chassis;

[0048] Figure 4 This is a schematic diagram of the structure of the rapid separation actuator of the present invention before the operation of the explosive bolt;

[0049] Figure 5 This is a schematic diagram of the structure of the rapid separation actuator of the present invention after the working of the explosive bolt;

[0050] Figure 6 This is a schematic diagram of the structure of the multifunctional composite material release device of the present invention;

[0051] Figure 7 This is a schematic diagram of the structure of the material before release and coating in this invention;

[0052] Figure 8 This is a schematic diagram of the material release and coating process of the present invention;

[0053] Figure 9 This is a schematic diagram of the structure after the material of the present invention is released and coated.

[0054] The attached diagram lists the components represented by each number as follows:

[0055] 1. Lead wire; 2. V-shaped fracture groove; 3. Activation device; 31. Protective cover; 32. Sliding block; 33. Electromagnet; 34. Iron ring; 4. Firing pin nozzle; 5. Firing pin; 6. Chassis mounting plate; 7. Activation device; 8. Explosive; 9. Bolt head; 10. Return spring; 11. Bolt; 12. Connecting screw hole; 13. Blocking ring; 14. Battery pack; 15. Special cabin; 16. Composite material compression tank; 17. Nozzle; 18. Solenoid valve; 19. Lead wire. Detailed Implementation

[0056] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0057] Example 1

[0058] See Figures 1 to 9 As shown, a thermal runaway emergency handling system for a power battery pack includes a sensing module, a central control unit, a rapid separation actuator, and a multi-functional composite material release device. The system is characterized in that: each module is connected via a CAN bus or a dedicated cable; the signal input from the sensing module is sent to the central control unit, and the output of the central control unit controls the rapid separation actuator and the multi-functional composite material release device.

[0059] The sensing module includes temperature sensors, a battery management system, a smoke sensor, and a collision sensor installed in the vehicle body, all distributed within the battery pack. The central control unit has preset multi-level judgment logic: for example, when a single temperature sensor exceeds a threshold and continues to rise, an early warning is issued; when multiple temperature sensors exceed thresholds and are accompanied by smoke signals, or when the collision acceleration exceeds a specific value and the temperature is abnormal, the highest-level trigger command is immediately generated.

[0060] The rapid separation actuator includes a chassis mounting plate 6 located at the bottom of the battery pack 14 storage compartment, connecting screw holes 12 located at the four corners of the chassis mounting plate 6 and the longitudinal beams of the vehicle chassis that are compatible with each other, a bolt 11 threaded into the connecting screw hole 12, a bolt head 9 installed at the bottom of the bolt, a hollow cavity located in the middle of the bolt 11, explosive 8, a firing device 7, a firing pin 5 and a firing pin port 4 placed in the hollow cavity from bottom to top, an excitation device 3 installed at the upper end of the connecting screw hole 12 and covering the bolt 11, and V-shaped fracture grooves 2 located on both sides of the lower end of the bolt 11.

[0061] The multifunctional composite material release device includes a dedicated chamber 15 located below the rear of the battery pack 14, a composite material compression tank 16 installed inside the dedicated chamber 15, a nozzle 17 located at the bottom of the dedicated chamber 15, a delivery pipe connecting the output end of the composite material compression tank 16 and the nozzle 17, a solenoid valve 18 installed in the middle of the delivery pipe, and a wire 19 connecting the solenoid valve 18 and the central control unit.

[0062] The excitation device 3 includes a protective cover 31 installed on the upper end of the connecting screw hole 12 and covering the bolt 11, an electromagnetic firing pin installed on the upper end of the protective cover 31, a blocking ring 13 set in the middle of the protective cover 31, and a return spring 10 connecting the electromagnetic firing pin and the blocking ring 13.

[0063] The electromagnetic firing pin includes a sliding block 32 slidably mounted on the upper end of the protective cover 31, an electromagnet 33 disposed on the outer ring of the sliding block 32, a firing pin mounted in the middle of the sliding block 32 and adapted to the firing pin port 4, an iron ring 34 disposed on the upper surface of the blocking ring 13, and an outgoing wire 1 connecting the electromagnet 33 and the central control unit.

[0064] Example 2

[0065] I. The working principle of the aforementioned rapid separation actuator is as follows:

[0066] S1, Electrical signal capture: When the vehicle monitoring system receives the battery thermal runaway signal, it sends a large instantaneous current to lead wire 1;

[0067] S2. Electromagnetic thrust generation: The electromagnet 33 on the excitation device generates a strong magnetic field, which instantly attracts the iron ring 34. At this time, the firing pin quickly strikes the firing pin 5.

[0068] S3. Activation of the firing device: The firing device 7 is activated by the impact detonation of the firing pin 5, which further ignites the explosive 8.

[0069] S4. Brittle fracture separation: The explosive 8 releases a large amount of high-pressure gas in a very short time. The pressure acts on the inner wall of the bolt 11, causing the weakest V-shaped fracture groove 2 to undergo brittle fracture.

[0070] S5. Battery detachment: With the breakage of bolt head 9, battery pack 14 loses physical constraint and detaches naturally under gravity.

[0071] II. The working principle of the multifunctional composite material release device is as follows:

[0072] S1, Trigger Control Unit: The solenoid valve 18 is activated after receiving a signal from the central control unit, and the solenoid valve 18 is opened.

[0073] S2. Composite material compression tank delivery: After the solenoid valve 18 is opened, the composite material compression tank 16 is connected to the nozzle 17. Under the action of high air pressure inside the composite material compression tank 16, the internal composite material flame retardant (liquid perfluorohexanone) is sprayed at high pressure onto the battery pack 14 for fire extinguishing and flame retardant.

[0074] S3, Mechanical linkage triggering mechanism: The signal of bolt 11 breaking is connected to the multi-functional composite material release device. Once triggered, the two devices work simultaneously to ensure that the spraying action and battery pack detachment are synchronized.

[0075] Example 3

[0076] The working principle of a thermal runaway emergency response system for a power battery pack is characterized by the fact that the system's workflow includes four stages: signal acquisition, logical judgment, action execution, and final protection. The specific steps are as follows:

[0077] S1. Signal Acquisition and Monitoring Phase: The system first monitors the battery pack status in real time using sensors in four dimensions:

[0078] Temperature sensor: monitors the thermal management status of the battery pack;

[0079] Collision sensors: monitor whether a vehicle has been involved in a physical collision;

[0080] Smoke sensor: Detects whether smoke is generated inside the battery pack in the early stages of thermal runaway;

[0081] Battery monitoring sensor: Monitors for abnormal electrical parameters such as voltage and current;

[0082] These four sets of sensors will transmit and summarize the collected data to the central control unit in real time.

[0083] S2, Logical Judgment Stage: The central control unit, as the core processing hub, analyzes and performs threshold comparisons on the received sensor signals.

[0084] Judgment Logic: The system determines whether the current state is extremely dangerous.

[0085] No (Safety / False Alarm): When the judgment result is "No", the system determines that no intervention is needed, the program execution stops, and the process directly enters the end state to avoid accidental operation.

[0086] Yes (Danger): When the judgment result is "Yes", it is confirmed as a dangerous situation, and the system immediately enters the trigger mode;

[0087] S3, Parallel Trigger Execution Phase: Once a dangerous situation is confirmed, the central control unit will simultaneously issue commands to trigger two subsystems in parallel:

[0088] Path A: Activate the rapid separation actuator to prepare for the physical separation of battery pack 14 from the vehicle body;

[0089] Path B: Activate the multifunctional composite material release device to prepare for the release of liquid perfluorohexanone;

[0090] S4. Action Interaction and Protection Phase: This is the core protection step of the system, involving two actions performed in tandem.

[0091] Battery pack detachment: The quick separation mechanism activates, causing the battery pack 14 to detach from the vehicle chassis, isolating the source of danger;

[0092] Covering functional materials: The release device sprays or covers a multifunctional composite material (liquid perfluorohexanone);

[0093] Two-way interaction: Covering occurs simultaneously with detachment, or the detachment action triggers the covering mechanism, ensuring that the battery is protected the instant it leaves the vehicle body;

[0094] S5. Final Stage: After the above actions, the battery is finally covered, achieving the goal of separating the hazardous battery from the vehicle and safely covering and sealing it; at this point, the entire safety protection process is complete.

Claims

1. A thermal runaway emergency handling system for a power battery pack, comprising a sensing module, a central control unit, a rapid separation actuator, and a multifunctional composite material release device, characterized in that: Each module is connected via a CAN bus or a dedicated cable; the signal input of the sensing module is sent to the central control unit, and the output of the central control unit controls the rapid separation actuator and the multi-functional composite material release device; The sensing module includes temperature sensors, a battery management system, a smoke sensor, and collision sensors installed in the vehicle body, all distributed within the battery pack; the central control unit has preset multi-level judgment logic. The rapid separation actuator includes a chassis mounting plate located at the bottom of the battery pack storage compartment, connecting screw holes located at the four corners of the chassis mounting plate and on the longitudinal beams of the vehicle chassis, bolts threaded into the connecting screw holes, bolt heads installed at the bottom of the bolts, a hollow cavity located in the middle of the bolts, explosives, a firing device, a firing pin and a firing pin port placed sequentially from bottom to top inside the hollow cavity, an excitation device installed at the upper end of the connecting screw holes and covering the bolts, and V-shaped fracture grooves located on both sides of the lower end of the bolts; The multifunctional composite material release device includes a dedicated compartment located on the side of the battery pack, a composite material compression tank installed inside the dedicated compartment, a nozzle located at the bottom of the dedicated compartment, a delivery pipe connecting the output end of the composite material compression tank and the nozzle, a solenoid valve installed in the middle of the delivery pipe, and a wire connecting the solenoid valve and the central control unit.

2. The thermal runaway emergency handling system for a power battery pack according to claim 1, characterized in that, The triggering device includes a protective cover installed on the upper end of the connecting screw hole and covering the bolt, an electromagnetic firing pin installed on the upper end of the protective cover, a blocking ring set in the middle of the protective cover, and a return spring connecting the electromagnetic firing pin and the blocking ring.

3. The thermal runaway emergency handling system for a power battery pack according to claim 2, characterized in that, The electromagnetic firing pin includes a sliding block slidably mounted on the upper end of the protective cover, an electromagnet disposed on the outer ring of the sliding block, a firing pin mounted in the middle of the sliding block and adapted to the firing pin opening, an iron ring disposed on the upper surface of the blocking ring, and lead wires connecting the electromagnet and the central control unit.

4. The thermal runaway emergency handling system for a power battery pack according to claim 1, characterized in that, The working principle of the rapid separation actuator is as follows: S1, Electrical signal capture: When the vehicle monitoring system receives the battery thermal runaway signal, it sends a large instantaneous current to the lead wire; S2. Electromagnetic thrust generation: The electromagnet on the excitation device generates a strong magnetic field, which instantly attracts the iron ring. At this time, the firing pin quickly strikes the firing pin. S3. Activation of the firing device: The firing device is activated by the impact detonation of the firing pin, which further ignites the explosive. S4. Brittle fracture separation: The explosive releases a large amount of high-pressure gas in a very short time. The pressure acts on the inner wall of the bolt, causing the weakest V-shaped fracture groove to undergo brittle fracture. S5. Battery detachment: As the bolt head breaks, the battery pack loses its physical constraint and detaches naturally under gravity.

5. The thermal runaway emergency handling system for a power battery pack according to claim 1, characterized in that, The working principle of the multifunctional composite material release device is as follows: S1, Trigger Control Unit: The solenoid valve is set to open after receiving a signal from the central control unit; S2. Composite material compression tank delivery: After the solenoid valve is opened, the composite material compression tank is connected to the nozzle. Under the action of high air pressure inside the composite material compression tank, the internal composite material flame retardant is sprayed onto the battery pack for fire extinguishing and flame retardant. S3. Mechanical linkage triggering mechanism: The signal of bolt breakage is connected to the multi-functional composite material release device. Once triggered, the two devices work simultaneously to ensure that the spraying action and battery pack detachment are synchronized.

6. The working principle of the thermal runaway emergency handling system for a power battery pack according to claim 1, characterized in that, The system's workflow consists of four stages: signal acquisition, logical judgment, action execution, and final protection. The specific steps are as follows: S1. Signal Acquisition and Monitoring Phase: The system first monitors the battery pack status in real time using sensors in four dimensions: Temperature sensor: monitors the thermal management status of the battery pack; Collision sensors: monitor whether a vehicle has been involved in a physical collision; Smoke sensor: Detects whether smoke is generated inside the battery pack in the early stages of thermal runaway; Battery monitoring sensor: Monitors for abnormal electrical parameters such as voltage and current; These four sets of sensors will transmit and summarize the collected data to the central control unit in real time. S2, Logical Judgment Stage: The central control unit, as the core processing hub, analyzes and performs threshold comparisons on the received sensor signals. Judgment Logic: The system determines whether the current state is extremely dangerous. No (Safety / False Alarm): When the judgment result is "No", the system determines that no intervention is needed, the program stops, and the process directly enters the end state to avoid accidental operation. Yes (Danger): When the judgment result is "Yes", it is confirmed as a dangerous situation, and the system immediately enters the trigger mode; S3, Parallel Trigger Execution Phase: Once a dangerous situation is confirmed, the central control unit will simultaneously issue commands to trigger two subsystems in parallel: Path A: Activate the rapid separation actuator to prepare for the physical separation of the battery pack from the vehicle body; Path B: Activate the multi-functional composite material release device to prepare for the release of fire extinguishing or heat insulation materials; S4. Action Interaction and Protection Phase: This is the core protection step of the system, involving two actions performed in tandem. Battery pack detachment: The quick separation mechanism activates, detaching the battery pack from the vehicle chassis and isolating it from the source of danger; Covering functional materials: The release device sprays or covers functional materials (such as fire extinguishing agents, fire blankets, etc.); Two-way interaction: Covering occurs simultaneously with detachment, or the detachment action triggers the covering mechanism, ensuring that the battery is protected the instant it leaves the vehicle body; S5. Final stage: After the above actions, the battery is finally covered, achieving the purpose of separating the hazardous battery from the vehicle and safely covering and sealing it. This concludes the entire security protection process.

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