Battery pack with thermal runaway prevention and control structure

Abstract

The invention discloses a battery pack with a thermal runaway prevention and control structure, and relates to the technical field of battery packs, the battery pack comprises a battery pack box body, the inner wall of the battery pack box body is provided with longitudinal and transverse beams, the inner wall of the battery pack box body is provided with a plurality of groups of battery cells on one side of the longitudinal and transverse beams, and the top of the battery pack box body is provided with a first mounting plate; a second mounting plate is in lap joint with the top of the first mounting plate, and a sealing top cover is mounted at the top of the second mounting plate; according to the battery pack with the thermal runaway prevention and control structure, a medium storage and injection closed-loop system comprising a storage box, a pump body, an extraction pipe, an output pipe, a conveying pipe and a spray head is integrated in the sealing top cover, so that the battery pack has autonomous, rapid and directional fire extinguishing and cooling capabilities; therefore, active intervention can be automatically implemented in the early stage of thermal runaway, and the coping mode that a traditional battery pack only depends on passive heat dissipation or external fire fighting is essentially changed.

Description

Technical Field

[0001] This invention relates to the field of battery pack technology, and more specifically to a battery pack with a thermal runaway prevention structure. Background Technology

[0002] With the booming development of the electric vehicle industry and the accelerated construction of energy storage power stations, the safety and reliability of battery packs, as the core components of energy storage and conversion, have become key factors restricting the further development of the industry. In particular, the risk of thermal runaway of battery packs increases significantly when there are high-rate charging and discharging, extreme ambient temperatures, or internal battery failures, which may lead to serious safety accidents such as fires and explosions. At present, the industry mainly relies on passive heat dissipation methods (such as natural cooling, air cooling, and liquid cooling) and alarm systems based on single temperature parameters to manage the thermal safety of battery packs. These methods are inadequate when dealing with complex and ever-changing thermal runaway scenarios.

[0003] However, the shortcomings of existing technologies lie in their over-reliance on a single temperature sensor for thermal runaway monitoring and control mechanisms. They lack the comprehensive perception capability of multi-physical field changes in the early stages of thermal runaway. Monitoring a single temperature parameter cannot capture early signs such as smoke and gas generated by electrolyte decomposition and material pyrolysis during battery thermal runaway in a timely manner. This makes it difficult for the early warning system to make accurate judgments and initiate effective intervention measures in the early stages of thermal runaway. This limitation means that existing battery packs often can only take post-event remedial measures when faced with sudden thermal runaway events, and cannot achieve active suppression in the early stages of thermal runaway, thus seriously threatening the safe operation of the battery pack and the entire system. Therefore, improvements are needed. Summary of the Invention

[0004] The purpose of this invention is to provide a battery pack with a thermal runaway prevention and control structure to solve the problem that the existing thermal runaway monitoring and prevention and control mechanisms rely too much on a single temperature parameter, making it difficult to achieve accurate identification and active intervention in the early stages of thermal runaway.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a battery pack with a thermal runaway prevention and control structure, comprising a battery pack housing, wherein longitudinal and transverse beams are installed on the inner wall of the battery pack housing, and multiple sets of battery cells are installed on one side of the inner wall of the battery pack housing located on the longitudinal and transverse beams, a first mounting plate is installed on the top of the battery pack housing, a second mounting plate overlaps the top of the first mounting plate, and a sealing top cover is installed on the top of the second mounting plate; Multiple storage boxes are installed on the inner wall of the sealed top cover. An assembly box is installed on the inner wall of each storage box. A pump body is installed on the inner wall of each assembly box. An extraction tube is installed at the input end of the pump body, and one end of the extraction tube is inserted into the inner wall of the storage box. An output tube is installed at the output end of the pump body. A sleeve is installed at the top end of the output tube. A delivery tube is inserted through the inner wall of the sleeve. Nozzles are installed on both sides of the delivery tube, and the bottom of the nozzles is positioned above the battery cell. A transmitter is installed on the inner wall of the sleeve. A temperature sensor is installed on one side of the sleeve, and a smoke sensor is installed at the other end of the sleeve. Both the temperature sensor and the smoke sensor are electrically connected to the transmitter.

[0006] Furthermore, a first socket frame is installed on one side of the sealed top cover, and a controller is installed on the inner wall of the first socket frame.

[0007] Furthermore, a partition plate is installed on the inner wall of the sealed top cover, the partition plate is located between the storage box and the sleeve pipe, and multiple sets of first mounting holes are opened through the top of the second mounting plate, and fixing bolts are threaded to the inner wall of the first mounting holes.

[0008] Furthermore, the top of the first mounting plate has multiple sets of second mounting holes, which are threaded into the fixing bolts.

[0009] Furthermore, a second socket frame is installed on one side of the battery pack housing, a transformer body is installed on the inner wall of the second socket frame, and a power connection port is installed on one side of the second socket frame.

[0010] Furthermore, an injection tube is installed on the top of the sealing top cover, the top end of the injection tube is threadedly connected to a sealing cap, and the bottom end of the injection tube is inserted into the inner wall of the storage box.

[0011] Furthermore, it also includes a thermal runaway detection and judgment system, which is used to receive and process signals collected by temperature sensors and smoke sensors, and determines that a thermal runaway state is triggered when the temperature exceeds a preset threshold and smoke is detected at the same time.

[0012] Furthermore, it also includes a medium release control system, which is used to automatically control the pump to start after the thermal runaway detection and judgment system determines that it has been triggered, and spray the medium in the storage tank onto the battery cell through the delivery pipe and nozzle.

[0013] Furthermore, it also includes a system status feedback system, which communicates with external devices through a controller to upload or display at least one of the following information: the determination status of the thermal runaway detection and judgment system, the start / stop status of the pump body, and the remaining status of the medium.

[0014] Furthermore, it also includes a system self-testing and fault diagnosis system, which periodically or in response to external commands detects the electrical connections and functional status of the temperature sensor, smoke sensor, pump body, and controller, and generates corresponding status reports or fault codes.

[0015] Compared with existing technologies, the present invention provides a battery pack with a thermal runaway prevention and control structure. By integrating a closed-loop system for medium storage and spraying, including a storage tank, pump body, extraction pipe, output pipe, delivery pipe and nozzle, inside the sealed top cover, the battery pack has autonomous, rapid and directional fire extinguishing and cooling capabilities. This enables automatic active intervention in the early stages of thermal runaway, fundamentally changing the traditional battery pack response mode that relies solely on passive heat dissipation or external fire fighting.

[0016] By setting up a real-time monitoring and intelligent judgment system for thermal runaway dual parameters integrated with temperature sensors, smoke sensors, and controllers, early and accurate identification of signs of thermal runaway is achieved, avoiding false alarms or missed alarms that may be caused by monitoring a single parameter. This significantly improves the accuracy of early warning and the timeliness of response, providing a reliable decision-making basis for the implementation of proactive suppression measures.

[0017] By setting up the communication interface between the system status feedback system and the controller, key safety information such as the status of thermal runaway events inside the battery pack, the action status of the prevention and control system, and the amount of dielectric material can be uploaded or displayed in real time to an external platform, thus enabling remote monitoring and maintenance and greatly improving the digitalization and visualization level of battery system safety management.

[0018] By setting up a system self-test and fault diagnosis system to perform periodic or command-based functional tests on core components such as sensors, pumps, and controllers, the system achieves automated management of its own health status. It can provide early warnings before component failure or accurately locate faults after they occur, thereby ensuring the continuous and reliable operation of this active safety system throughout its entire life cycle and avoiding the risk of unsafe safety devices.

[0019] The independent, maintainable media storage unit, consisting of a storage tank, injection pipe, and sealing cap, allows for easy inspection, replenishment, and replacement of the fire-extinguishing and cooling inhibitor without disassembling the main battery pack structure. This ensures the durability of the fire prevention and control performance and significantly reduces the long-term maintenance costs and complexity of the system. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0021] Figure 1 This is a schematic diagram of the overall structure provided for an embodiment of the present invention; Figure 2 This is a schematic diagram of the main structure of a transformer provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the controller structure provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the storage box structure provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the pump body structure provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of the nozzle structure provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of the sleeve structure provided in an embodiment of the present invention.

[0022] Explanation of reference numerals in the attached figures: 1. Battery pack housing; 2. Longitudinal and transverse beams; 3. Battery cell; 4. First mounting plate; 5. Second mounting plate; 6. Sealed top cover; 7. Storage box; 8. Assembly box; 9. Pump body; 10. Extraction pipe; 11. Output pipe; 12. Socket pipe; 13. Delivery pipe; 14. Nozzle; 15. Temperature sensor; 16. Smoke sensor; 17. First socket frame; 18. Controller; 19. Partition plate; 20. First mounting hole; 21. Fixing bolt; 22. Second mounting hole; 23. Second socket frame; 24. Transformer body; 25. Power connection port; 26. Injection pipe; 27. Sealed cover. Detailed Implementation

[0023] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0024] As attached Figure 1 To be continued Figure 7 As shown: Example 1: The present invention provides a battery pack with a thermal runaway prevention structure, including a battery pack housing 1, longitudinal and transverse beams 2 installed on the inner wall of the battery pack housing 1, multiple sets of battery cells 3 installed on one side of the inner wall of the battery pack housing 1 located on the longitudinal and transverse beams 2, a first mounting plate 4 installed on the top of the battery pack housing 1, a second mounting plate 5 overlapping the top of the first mounting plate 4, and a sealing top cover 6 installed on the top of the second mounting plate 5. Multiple storage boxes 7 are installed on the inner wall of the sealed top cover 6. An assembly box 8 is installed on the inner wall of the storage box 7. A pump body 9 is installed on the inner wall of the assembly box 8. An extraction pipe 10 is installed at the input end of the pump body 9, with one end of the extraction pipe 10 inserted into the inner wall of the storage box 7. An output pipe 11 is installed at the output end of the pump body 9. A sleeve pipe 12 is installed at the top of the output pipe 11. A delivery pipe 13 is inserted through the inner wall of the sleeve pipe 12. Nozzles 14 are installed on both sides of the delivery pipe 13, with the bottom of the nozzles 14 positioned above the battery cell 3. The sleeve pipe 1... A transmitter is installed on the inner wall of the 2. A temperature sensor 15 is installed on one side of the sleeve 12 and a smoke sensor 16 is installed on the other end of the sleeve 12. Both the temperature sensor 15 and the smoke sensor 16 are electrically connected to the transmitter. A first socket frame 17 is installed on one side of the sealed top cover 6. A controller 18 is installed on the inner wall of the first socket frame 17. An injection pipe 26 is installed on the top of the sealed top cover 6. A sealing cap 27 is threaded to the top of the injection pipe 26, and the bottom end of the injection pipe 26 is inserted into the inner wall of the storage box 7.

[0025] In use, the battery pack housing 1 serves as the main load-bearing structure of the battery pack. Its interior is divided by longitudinal and transverse beams 2 to provide a stable mounting base and enhance overall structural strength. These beams not only provide support but also effectively isolate the individual battery cells 3, preventing rapid heat spread between cells during thermal runaway. The battery cells 3, as the core energy storage units of the battery pack, are arranged systematically within the areas defined by the longitudinal and transverse beams 2 inside the battery pack housing 1. A first mounting plate 4 is fixed to the top of the battery pack housing 1 to support the upper components. A second mounting plate 5 overlaps above it, together forming a multi-layered mounting platform that facilitates the layered arrangement of electrical and structural components. A sealed top cover 6 is installed above the second mounting plate 5, forming the upper enclosed space of the battery pack, providing sealing and protection. Multiple storage boxes 7 are installed inside the sealed top cover 6 to store fire extinguishing or cooling media. Assembly boxes 8 are installed inside the storage boxes 7 to secure the pump body 9. Pump body 9, as the core component for fluid delivery, has its input end connected to the inside of storage tank 7 via extraction pipe 10, allowing it to extract media from storage tank 7. Its output end is connected to sleeve pipe 12 via output pipe 11. Sleeve pipe 12 serves as a fluid distribution and sensor integration unit, with a delivery pipe 13 inserted through it. Multiple nozzles 14 are installed on both sides of delivery pipe 13, positioned directly above the area above the battery cell 3, enabling precise spraying of media for cooling or fire suppression upon triggering. Sleeve pipe 12 also integrates a transmitter for receiving and forwarding sensor signals; a temperature sensor 15 is installed on one side for real-time monitoring of the battery cell. Temperature changes in the area are monitored, and a smoke sensor 16 is installed on the other side to detect smoke signals that may be generated in the early stages of thermal runaway. Both the temperature sensor 15 and the smoke sensor 16 are electrically connected to a transmitter to achieve real-time transmission of monitoring data. A first socket frame 17 is installed on one side of the sealed top cover 6, and a controller 18 is fixed inside it. The controller 18 is responsible for receiving sensor signals and controlling the start and stop of actuators such as the pump body 9 to achieve automatic thermal runaway response. In addition, an injection pipe 26 is also provided on the top of the sealed top cover 6 for replenishing the medium into the storage tank 7. The top of the injection pipe 26 is connected to a sealing cap 27 by threads to ensure the airtightness of the storage system. The above structures together constitute an integrated and rapid-response thermal runaway monitoring and prevention system, which effectively improves the safety protection capability of the battery pack in the event of thermal runaway through real-time monitoring, intelligent judgment and active injection of medium.

[0026] The medium is a battery thermal runaway inhibitor, typically a liquid compound with high specific heat capacity, good insulation, and flame retardant properties, such as a fluorinated inert liquid, lithium hydroxide solution, or a flame-retardant coolant with a specific formulation. This medium maintains liquid stability at room temperature and rapidly vaporizes to absorb heat at high temperatures, effectively reducing the temperature of the battery cell surface and surrounding environment. Simultaneously, its components block oxygen supply, inhibit the combustion of flammable gases, and form a heat-insulating layer upon contact with high-temperature surfaces, preventing heat spread. Driven by pump 9, the medium is delivered through delivery pipe 13 to nozzle 14, precisely covering the surface of battery cell 3 and its surrounding area in the form of atomization, spraying, or diffusion. When temperature sensor 15 or smoke sensor 16 detects signs of thermal runaway, the controller 18 automatically triggers release, achieving rapid cooling, oxygen isolation, or chemical inhibition, preventing heat spread and fire. The design of injection pipe 26 and sealing cap 27 facilitates regular inspection, replenishment, or replacement of the medium, ensuring long-term reliable system operation.

[0027] When one or more cells within a battery pack enter an abnormal state, the thermal runaway process is typically accompanied by a rapid increase in temperature and trace amounts of smoke generated from electrolyte decomposition and material pyrolysis. Temperature and smoke sensors mounted on the bushing above the cells continuously collect these physical signals. These signals are transmitted to the controller via a transmitter inside the bushing. The controller's embedded thermal runaway detection and judgment algorithm performs real-time analysis and logical judgment on these two parameters: only when the temperature signal in the monitored area continuously exceeds a preset safety threshold (e.g., 80°C or higher, depending on the cell's chemical system), and the smoke sensor simultaneously detects smoke particles at a concentration exceeding the background level, does the system determine a clear thermal runaway trigger event. This effectively avoids false alarms caused by a single temperature parameter potentially due to localized hotspots or environmental interference.

[0028] Once thermal runaway is confirmed, the system immediately switches from monitoring mode to execution mode. The controller sends a command to the medium release control system to activate the pump inside the storage tank assembly box. The pump, acting as a power source, rapidly extracts pre-filled battery thermal runaway inhibitor fluid from the storage tank through its input extraction pipe. This inhibitor fluid is typically a liquid compound with high latent heat of vaporization, good insulation, and flame-retardant properties. After pressurizing the inhibitor fluid, the pump delivers it through the output pipe to the bushing, which serves as a fluid distribution hub, and then into the delivery pipe, which is connected to the bushing. Multiple precisely designed nozzles are arranged along both sides of the delivery pipe. The installation position and spray angle of these nozzles are optimized to ensure that their coverage area directly targets the top and upper sides of each battery cell, as well as critical heat sources and gas release areas.

[0029] When the suppressant reaches the nozzle under pressure, it is atomized into fine droplets or sprayed out as a directional jet. The atomized droplets have a large specific surface area, rapidly covering the cell surface and surrounding space. Upon contact with the high-temperature cell surface or surrounding high-temperature gas, the suppressant undergoes violent vaporization. This phase change process absorbs a large amount of heat, rapidly and efficiently reducing the temperature of the cell and the local environment, preventing further temperature spikes. Simultaneously, the components of the suppressant decompose or function at high temperatures, forming an oxygen barrier or releasing free radical scavengers. This effectively isolates the oxygen supply and inhibits the chain combustion reaction of combustible gases (such as hydrogen and carbon monoxide), extinguishing any potential open flames in the early stages of thermal runaway and preventing the spread of flames and heat to adjacent cells. The entire spraying process is controlled by a controller, which dynamically adjusts the pump power based on the rate or gradient of temperature rise to control the spray flow and duration, achieving optimal suppression effect and media economy. After the spraying ends, the system status feedback module will upload the action record and current status, while the system self-check module will ensure that all sensors and actuators are still in normal standby status after the event, thus forming a complete spraying prevention and control closed loop that is responsive, accurate in judgment and effective in action.

[0030] Example 2: This embodiment is basically the same as the previous embodiment, except that a partition plate 19 is installed on the inner wall of the sealed top cover 6. The partition plate 19 is located between the storage box 7 and the sleeve pipe 12. Multiple sets of first mounting holes 20 are opened through the top of the second mounting plate 5. The inner wall of the first mounting hole 20 is threaded with a fixing bolt 21. Multiple sets of second mounting holes 22 are opened through the top of the first mounting plate 4. The second mounting holes 22 and the fixing bolts 21 are threaded together. A second socket frame 23 is installed on one side of the battery pack box 1. A transformer body 24 is installed on the inner wall of the second socket frame 23. A power connection port 25 is installed on one side of the second socket frame 23.

[0031] In use, the partition plate 19 divides the internal space of the sealed top cover 6 into functional areas, effectively isolating the storage box 7 and the area where the sleeve pipe 12 is located, preventing interference between the medium storage area and the electrical sensing area, and improving structural stability and safety. The first mounting hole 20 is opened on the top of the second mounting plate 5, corresponding to the second mounting hole 22 on the first mounting plate 4. By passing through the two with the fixing bolt 21 and tightening it, a reliable connection between the first mounting plate 4 and the second mounting plate 5 can be achieved, ensuring clear installation layers and a solid overall structure. The second sleeve frame 23 is fixed to one side of the battery pack housing 1, providing an independent mounting cavity for the transformer body 24, isolating it from the main circuit of the battery pack, which facilitates heat dissipation and reduces electromagnetic interference. The transformer body 24 is used for voltage conversion and is directly related to the electrical system of the battery cell 3, providing a suitable working voltage for the battery pack. A power connection port 25 is provided on one side of the second sleeve frame 23. The power connection port 25 serves as the connection interface between the external power supply and the internal electrical system of the battery pack, used to charge the battery cell 3 or connect to an external load to realize the input and output of electrical energy.

[0032] Example 3: This embodiment is basically the same as the previous embodiment, except that it also includes a thermal runaway detection and judgment system. The thermal runaway detection and judgment system is used to receive and process the signals collected by the temperature sensor 15 and the smoke sensor 16, and determines that a thermal runaway state is triggered when the temperature exceeds a preset threshold and smoke is detected at the same time. It also includes a medium release control system, which is used to automatically control the pump body 9 to start after the thermal runaway detection and judgment system determines that the thermal runaway state is triggered, and spray the medium in the storage tank 7 to the battery cell 3 through the delivery pipe 13 and the nozzle 14. It also includes a system status feedback system, which communicates with external devices through the controller 18 to upload or display at least one of the following information: the judgment status of the thermal runaway detection and judgment system, the start / stop status of the pump body 9, and the remaining status of the medium. It also includes a system self-test and fault diagnosis system, which periodically or in response to external commands detects the electrical connection and functional status of the temperature sensor 15, the smoke sensor 16, the pump body 9, and the controller 18, and generates corresponding status reports or fault codes.

[0033] The thermal runaway detection and judgment system also includes a signal filtering and anti-interference unit, used to filter sensor signals and avoid false triggering due to transient interference. The medium release control system includes a flow regulation unit, which can dynamically adjust the output flow of pump 9 according to the temperature gradient detected by temperature sensor 15. The system status feedback system supports wired or wireless communication protocols and can send the system operating status to a remote monitoring platform in real time. When a fault is detected, the system self-test and fault diagnosis system can automatically switch to a backup sensor or execute a preset safety shutdown procedure.

[0034] Application example: This battery pack is suitable for various electrochemical energy storage and power battery applications with stringent thermal safety requirements, especially in electric vehicles, energy storage power stations, industrial backup power supplies, and high-power mobile devices. In these applications, the battery pack poses a significant risk of thermal runaway when operating at high rates for extended periods, in high-temperature environments, or experiencing internal faults such as internal short circuits. In severe cases, this can lead to fires or even explosions. Traditional battery pack thermal management typically relies on external heat dissipation or simple temperature alarms, which are insufficient for rapid response and active suppression in the early stages of thermal runaway. This application example describes how, under actual operating conditions, this battery pack with a thermal runaway prevention structure, through its integrated monitoring and active suppression system, achieves early warning and effective intervention against potential thermal runaway risks, ensuring the safety of the vehicle and personnel.

[0035] This battery pack is put into operation after being assembled into the electric vehicle chassis. During normal vehicle operation or charging, the multiple cells 3 inside it continue to work. The battery pack housing 1 provides mechanical protection and environmental sealing for the entire battery pack, and the internal longitudinal and transverse beams 2 physically isolate each group of cells 3 to limit the lateral spread of potential thermal runaway events.

[0036] The thermal runaway monitoring system remains in standby mode. Temperature sensor 15 and smoke sensor 16, installed on the bushing 12, monitor the environmental conditions above the cell 3 area in real time. Temperature sensor 15 continuously collects temperature data, while smoke sensor 16 monitors for abnormal smoke particles. The analog signals collected by the two sensors are preliminarily processed and converted into digital signals by a transmitter integrated within the bushing 12, and then transmitted via lines to the controller 18 installed within the first bushing frame 17. The thermal runaway detection and judgment system software running within the controller 18 analyzes the received temperature and smoke signals in real time and compares them with preset temperature thresholds and smoke judgment logic. When the controller 18 simultaneously determines that the temperature signal in a certain area continuously exceeds the preset safety threshold, and the smoke sensor 16 simultaneously detects an abnormally concentrated smoke signal, the system determines that thermal runaway has been triggered in that area of ​​cell 3.

[0037] Once the thermal runaway detection and judgment system makes a trigger determination, the linked medium release control system is immediately activated. Controller 18 sends a start command to pump 9. Pump 9 then begins operation, its input end rapidly drawing pre-stored battery thermal runaway-specific inhibitory fluid from storage tank 7 through extraction pipe 10. After being pressurized by pump 9, the inhibitory fluid is delivered to sleeve pipe 12 via output pipe 11, and then enters delivery pipe 13 connected to sleeve pipe 12. Multiple nozzles 14 arranged on both sides of delivery pipe 13 accurately and evenly spray the inhibitory fluid in the form of atomization or fine jet onto the surface of the battery cell 3 below and adjacent areas where thermal runaway has been determined to have occurred. The positioning of nozzles 14 ensures that the medium can cover the top and side critical heat source areas of the target battery cell 3. The rapid release of the medium can achieve rapid heat absorption and cooling, isolate oxygen, and inhibit the chain reaction of flammable gases, thereby curbing the development of thermal runaway in its early stages.

[0038] Throughout the monitoring and response process, the system status feedback system operates synchronously. The controller 18, through its integrated communication interface (such as a CAN bus or wireless module), uploads information in real time to the vehicle's onboard gateway or remote monitoring platform, including the determination status of the thermal runaway event, the start-up and operating status of the pump 9, and the remaining medium status indirectly calculated by monitoring the operating parameters of the pump 9 or the liquid level in the storage tank 7. This allows the driver or maintenance personnel to immediately know the battery pack's safety status and take appropriate measures, such as safely stopping the vehicle, requesting roadside assistance, or arranging maintenance.

[0039] In addition, to ensure the long-term reliability of the control system, the system self-test and fault diagnosis system is activated every time the vehicle is powered on or during regular maintenance. This system sends test commands to key components such as the temperature sensor 15, smoke sensor 16, and pump 9 via controller 18, and checks their feedback signals, the integrity of electrical connections, and the normality of functional responses. If faults such as excessive sensor signal drift, pump 9 stalling, or open circuit are detected, the system generates a status report containing specific fault codes and component locations, and uploads it to the diagnostic interface or display terminal via controller 18 to guide maintenance personnel in targeted repairs or component replacement. The partition plate 19 ensures that the storage tank 7 area is isolated from the sleeve pipe 12 area containing sensors and wiring, preventing potential media leakage or condensation from corroding electrical components and improving the system's environmental tolerance and long-term stability. When the inhibitor needs to be replenished or replaced, maintenance personnel can unscrew the sealing cap 27 and add the medium into the storage tank 7 through the injection pipe 26, a simple operation that ensures the storage system can be resealed. The battery pack is electrically connected to the vehicle's high-voltage system via the power interface 25. The required voltage conversion is accomplished by the transformer body 24 installed in the second socket 23, ensuring that the battery cell 3 operates within the appropriate voltage range.

[0040] Working Principle: The battery pack housing 1 provides basic structural support and external encapsulation for the entire battery pack. Internal longitudinal and transverse beams 2 divide the internal space into multiple independent units, each housing a set of battery cells 3. The beams 2 not only provide physical support but also effectively prevent direct heat and flame transfer between adjacent battery cells 3 during thermal runaway. A first mounting plate 4 and a second mounting plate 5 are sequentially installed on the top of the battery pack, forming a layered mounting platform. The top is completely sealed by a sealing top cover 6. The sealing top cover 6 integrates multiple storage boxes 7 for storing battery thermal runaway inhibitory fluid. The storage boxes 7 contain assembly boxes 8 for fixing the pump body 9. When a battery cell 3 inside the battery pack enters the initial stage of thermal runaway due to a certain reason, the temperature sensor 15 installed on the sleeve 12 will detect an abnormal temperature rise in that area. Simultaneously, the smoke sensor 16 will detect trace amounts of smoke generated by electrolyte decomposition or material pyrolysis. The signals from these two sensors are transmitted in real-time to the controller 18 via a transmitter inside the sleeve 12. The thermal runaway detection and judgment system running inside the controller 18 analyzes the received signals. When the temperature exceeds a preset safety threshold and smoke is detected simultaneously, thermal runaway is confirmed to have been triggered. Immediately, the controller 18 activates the medium release control system, sending a working command to the pump 9. After the pump 9 starts, it draws inhibitory liquid from the storage tank 7 through the extraction pipe 10, pumps it through the output pipe 11 to the bushing pipe 12, then distributes it to the delivery pipe 13 running through it, and finally sprays the inhibitory liquid precisely onto the surface of the battery cell 3 and the surrounding area where thermal runaway has occurred through nozzles 14 evenly distributed on both sides of the delivery pipe 13. The inhibitory liquid rapidly vaporizes and absorbs heat to lower the temperature, while its flame-retardant components isolate oxygen and inhibit chain combustion reactions, thereby quickly extinguishing early flames and preventing heat spread. Throughout the process, the system status feedback system uploads information such as the event status and the working status of the pump 9 to an external monitoring terminal via the controller 18. In addition, the system self-test and fault diagnosis system periodically or under control performs self-tests on temperature sensor 15, smoke sensor 16, pump body 9, and controller 18 to ensure that the system is always in a reliable standby state. Injection pipe 26 and sealing cap 27 constitute the medium filling and sealing channel. Partition plate 19 physically isolates the storage tank 7 area from the sensor and pipeline areas to prevent mutual interference. First mounting plate 4 and second mounting plate 5 are fastened together by fixing bolts 21 passing through first mounting hole 20 and second mounting hole 22. The transformer body 24 installed in the second socket 23 is responsible for voltage conversion, and the power connection port 25 is responsible for external electrical connections. Through the coordinated work of the above structures, the battery pack achieves real-time monitoring, intelligent judgment, active suppression, and status feedback of thermal runaway risks, forming a complete closed-loop safety control system.

[0041] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A battery pack with a thermal runaway prevention structure, comprising a battery pack housing (1), characterized in that, The inner wall of the battery pack housing (1) is equipped with longitudinal and transverse beams (2). Multiple sets of battery cells (3) are installed on one side of the inner wall of the battery pack housing (1) located on the longitudinal and transverse beams (2). A first mounting plate (4) is installed on the top of the battery pack housing (1). A second mounting plate (5) overlaps the top of the first mounting plate (4). A sealing top cover (6) is installed on the top of the second mounting plate (5). The inner wall of the sealed top cover (6) is equipped with multiple storage boxes (7), the inner wall of the storage box (7) is equipped with an assembly box (8), the inner wall of the assembly box (8) is equipped with a pump body (9), the input end of the pump body (9) is equipped with an extraction pipe (10), and one end of the extraction pipe (10) is inserted into the inner wall of the storage box (7). The output end of the pump body (9) is equipped with an output pipe (11), and the top end of the output pipe (11) is equipped with a sleeve pipe (12). A delivery pipe (13) is inserted through the inner wall of the battery cell (3). A nozzle (14) is installed on both sides of the delivery pipe (13), and the bottom of the nozzle (14) is located above the battery cell (3). A transmitter is installed on the inner wall of the sleeve (12). A temperature sensor (15) is installed on one side of the sleeve (12), and a smoke sensor (16) is installed on the other end of the sleeve (12). The temperature sensor (15) and the smoke sensor (16) are electrically connected to each other with the transmitter.

2. A battery pack with a thermal runaway prevention structure according to claim 1, characterized in that, A first socket frame (17) is installed on one side of the sealed top cover (6), and a controller (18) is installed on the inner wall of the first socket frame (17).

3. A battery pack with a thermal runaway prevention structure according to claim 1, characterized in that, The inner wall of the sealed top cover (6) is equipped with a partition plate (19), which is located between the storage box (7) and the sleeve pipe (12). The top of the second mounting plate (5) has multiple sets of first mounting holes (20), and the inner wall of the first mounting holes (20) is threaded with fixing bolts (21).

4. A battery pack with a thermal runaway prevention structure according to claim 3, characterized in that, The top of the first mounting plate (4) has multiple sets of second mounting holes (22), which are threadedly engaged with the fixing bolts (21).

5. A battery pack with a thermal runaway prevention structure according to claim 1, characterized in that, A second socket (23) is installed on one side of the battery pack housing (1), a transformer body (24) is installed on the inner wall of the second socket (23), and a power connection port (25) is installed on one side of the second socket (23).

6. A battery pack with a thermal runaway prevention structure according to claim 1, characterized in that, An injection tube (26) is installed on the top of the sealing top cover (6). The top end of the injection tube (26) is threadedly connected to a sealing cover (27), and the bottom end of the injection tube (26) is inserted into the inner wall of the storage box (7).

7. A battery pack with a thermal runaway prevention structure according to claim 1, characterized in that, It also includes a thermal runaway detection and judgment system, which is used to receive and process the signals collected by the temperature sensor (15) and the smoke sensor (16), and determines that a thermal runaway state is triggered when the temperature exceeds a preset threshold and smoke is detected at the same time.

8. A battery pack with a thermal runaway prevention structure according to claim 1, characterized in that, It also includes a medium release control system, which is used to automatically control the pump body (9) to start after the thermal runaway detection and judgment system determines that it is triggered, and spray the medium in the storage tank (7) onto the battery cell (3) through the delivery pipe (13) and the nozzle (14).

9. A battery pack with a thermal runaway prevention structure according to claim 2, characterized in that, It also includes a system status feedback system, which communicates with external devices through a controller (18) to upload or display at least one of the following information: the judgment status of the thermal runaway detection and judgment system, the start / stop status of the pump body (9), and the remaining status of the medium.

10. A battery pack with a thermal runaway prevention structure according to claim 2, characterized in that, It also includes a system self-test and fault diagnosis system, which periodically or in response to external commands, detects the electrical connection and functional status of the temperature sensor (15), smoke sensor (16), pump body (9) and controller (18), and generates corresponding status reports or fault codes.

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