Aerosol fire suppression materials, systems, and methods of implementation

Abstract

Fire protection and suppression devices, fire protection and suppression materials, fire protection and suppression systems, and methods of use thereof are disclosed. In fire suppression applications, the aerosol extinguishing agent in sheets, panels, or other forms may be placed in a variety of mounting locations, including, but not limited to, within an enclosure containing the fire hazard, one or more within the fire hazard itself, or may be incorporated into the structure of the fire hazard. Upon initiation, the aerosol extinguishing material burns to generate and directly disperse aerosol particles capable of extinguishing a fire. The aerosol agent may be initiated by flame or heat from an unwanted fire. Alternative initiation methods include an automatic fire detection system, an electrical manual method, or an electrical initiator signaled by a mechanical / thermal initiator.

Description

[Technical field]

[0001] The present invention relates to fire protection and suppression devices, fire protection and suppression materials, fire protection and suppression systems, particularly for use in locations such as compartments and enclosures, and methods of use thereof.

[0002] The present invention relates to the use of aerosol extinguishing agents in simplified systems which simplify the system, reduce space requirements, and reduce weight, lowering costs in both extinguishing components and equipment.

[0003] More specifically, the present invention relates in part to solid aerosol fire extinguishing agents that are formed into panels, sheets or various shapes as materials to be inserted into voids within hazardous materials, as materials used to form structures or parts of hazardous materials, or as coverings that may be employed in compartments or enclosures without the need for large housings or containers. [Background technology]

[0004] In North America, we typically refer to four fire classes: A, B, C, and D. Other regions, such as Europe, may have similar methods but different names. Class A is the burning of common combustible materials such as wood, paper, etc. Class B is the burning of flammable liquids such as alcohol and gasoline. Class C, "electrical fires," requires some explanation. Electricity itself does not burn, but it is an ignition source. What burns are materials that behave as Class A and / or Class B materials, typically electrical insulation made from plastic type products. Class A fire behavior is due to bundles, i.e., electrical wires, where the problem is getting the extinguishing agent to penetrate deep enough into the wire bundle, as would be necessary if the burning cable were in the center of the bundle. Class B fire behavior occurs when the plastic melts before it begins to burn.

[0005] If a fire occurs due to an electrical ignition source, there are two scenarios: 1. When power is turned off, automatically or manually, a "de-energized" fire becomes a Class A or Class B fire, or both. It is still important to realize that plastics can have both A and B behavior. 2. If the power is not turned off, it is a live electrical fire which is much more difficult to put out because the ignition source is still present. Some electrical fires may not be put out until the power source is removed.

[0006] Live electrical fires can be extremely dangerous because they are difficult, if not impossible, to extinguish and because of the risk of electric shock.

[0007] As of this writing, Underwriters' Laboratories™ rates extinguishers as A-list, B-list, C-list, and / or D-list, depending on the type of fire the extinguisher may be used on. The "C" list simply means that the extinguishing agent is normally not conductive (electricity does not flow through the extinguisher discharge stream and back to the extinguisher operator). It does not certify the extinguisher's effectiveness against all energized electrical fires.

[0008] Class D is a combustible metal fire. Magnesium, very fine aluminum, etc.

[0009] fire suppression terminology Flame retardants Fire retardants are applied to slow the spread of fire, usually by reducing the flammability of the fuel. for example, In forest firefighting, aircraft drop large amounts of water in front of an advancing forest fire; the water typically contains chemical additives that make the trees and shrubs on the ground less flammable, thus slowing the fire's progress. If aimed directly at the fire, the water can extinguish it, but its main job is containment. Also, significant amounts of water are needed from aircraft to put out a forest fire, and the available water is more effective if the fire's spread is prevented. Flame retardants are typically employed to slow the progression of a fire rather than to extinguish it.

[0010] Fire suppressants The term "fire suppressant" can be confusing. This term indicates that the agent will suppress a particular fire, but not necessarily extinguish it. Of course, the true goal is to extinguish the fire, but the best goal that can be achieved with a particular agent against a particular fire is to weaken or slow the fire. In other words, in some applications extinguishing the fire is achieved and in other applications extinguishing is not achieved. Some fire suppression system manufacturers advertise their products as "fire suppression systems" when they do not necessarily achieve extinguishing the fire. This is sometimes done to avoid calling their products "fire suppression systems" as a product liability measure. However, potential buyers should be wary of the term "suppression system" or carefully review the agent's functionality in relation to the application, since what the customer really wants is a "fire suppression system." A common good example is halocarbon gas agents for Class A fires. If the burning Class A material is minor, such as a writing paper or wastebasket fire on a desk, the system may extinguish these fires. Or, if the burning Class A material is a disassembled cardboard shipping box placed on a shelf, the halocarbon agent may have a much harder time penetrating the fire area within these materials, and the fire will only be suppressed, not extinguished. Thus, fire protection system manufacturers refer to their systems as suppression systems.

[0011] Fire extinguishing agent The extinguishing agent will extinguish the fire. These systems are far superior to fire retardants or fire suppressants. To address fire hazards, such as battery fire hazards, Fire retardants and suppressants must be avoided because battery fires are violent and difficult to extinguish. The only systems that make sense are those that can extinguish the fire quickly and can withstand the fire long enough for the hazard to cool and stop posing a risk of runaway.

[0012] Types of Fire Extinguishers There is no universal agent (although aerosols come close). The "traditional" agents used for each fire classification are: Class A Water, Multi-Purpose Dry Chemical Class B Foam, dry chemicals, carbon dioxide Class C Multipurpose Dry Chemical, Carbon Dioxide Class D (sand-like) special dry powder

[0013] Lithium-ion battery fire As the use of batteries, such as lithium-ion batteries in electric vehicles, becomes more prevalent, there is growing interest in improving the operational safety of such battery-based power systems. Although there are multiple types of lithium-ion batteries with different technologies, this "family" of batteries all share similar fire suppression challenges.

[0014] Lithium-ion battery fires are unique because they can cause Class A, Class B, Class C and Class D fires all at once.

[0015] The main hazard issue is the stored energy, other hazards are the flammable electrolyte, the highly flammable lithium metal, and the packaging materials, which can generate their own oxygen in the event of a fire.

[0016] When considering lithium-ion battery fire extinguishing, there are a few points to note in particular: Batteries are capable of very high energy storage. The initiation of a fire or explosion can be highly unpredictable. The fire or explosion may progress very quickly, sometimes with only a few seconds between initiation and explosion or uncontrollable fire. The problem has two "stages." Destructive opening of the packaging and initiation of fire / explosion, Rapid uncontrolled heating of battery remains, rapid exposure of adjacent batteries to heat and spread of fire / explosion; Conventional fire extinguishing agents do not work; and Water does not work well as a fire extinguishing agent, but large amounts of water can cool hazardous materials and may ultimately end a fire.

[0017] Regarding the use of aerosols in fire suppression and extinguishing, thin metal panels containing dry chemical extinguishing powder are placed around the fuel tank of an automobile so that if the vehicle is rear-ended, the fuel tank may burst, which will also burst the panel containing the extinguishing agent, thus dispersing the dry powder agent to prevent or extinguish the fire. Some Ford Crown Victoria police vehicles have been fitted with these dry chemical agent panels, which have been successful in suppressing fires in both tests and in actual accidents. The U.S. military also installs similar panels on armored vehicles to protect wheel wells, etc. No aerosol agents are used in these applications.

[0018] Dry chemical agents, usually made with sodium or potassium bicarbonate, are stored and released as fine powders with particles typically measuring 25 microns in diameter. When these powders enter a fire, they extinguish it primarily by interrupting the fire's chemical reactions.

[0019] Aerosol agents, usually made of a fuel (such as epoxy resin) mixed with an oxidizer (such as potassium nitrate), are solid, combustible materials that burn when exposed to flame or high heat. The products of combustion are fine, aerosol-sized particles with much smaller diameters (less than 10 microns, typically less than 2 microns in diameter) and modest amounts of nitrogen and other gases.

[0020] The National Fire Protection Association (NFPA Standard 2010 Standard for Fixed Aerosol Fire-Extinguishing Systems, Section 3.3.2.1) defines "condensation aerosol" as follows: "An extinguishing medium consisting of finely divided solid particles generally less than 10 microns in diameter and gaseous matter produced by the combustion process of solid aerosol-forming compounds." This is a refinement of the more commonly understood meaning of "very" finely divided solid or liquid particulate matter. Summary of the Invention [Means for solving the problem]

[0021] According to an embodiment of the present invention, the condensation aerosol material implemented has two states: a solid state (which is a compound or precursor material in the form of a rigid or semi-rigid panel, flexible sheet, block (such as a rectangular prism), or three-dimensional solid (such as a tetrahedron or pyramid) that generates a fire-suppressing aerosol after ignition), and an aerosol-generating state which includes finely divided solid or liquid particles after ignition.

[0022] These fine aerosol particles also extinguish fires by interrupting the chemical reactions of the fire, and because of their small diameter, the surface area of ​​the agent particles is greatly increased, allowing the particles to react very quickly in the flame compared to other agents, resulting in much more rapid extinguishing performance.

[0023] Combining an agent using a chemical interruption mechanism with the ability to react quickly in a flame makes the agent highly efficient compared to other agents, requiring much less agent.

[0024] In an embodiment of the present invention, a fire suppression system includes: an enclosure having at least one enclosure wall defining an interior volume; an internal compartment structure dividing the internal volume into at least two separate sub-volumes; At least one of the enclosure wall and the interior compartment structure is fabricated from a matrix including an aerosol fire suppression material and a flammable substrate. At least one of the following is provided:

[0025] Panels, sheets, various forms and coverings of solid or flexible condensation aerosol fire extinguishing materials can be ignited by fire or heat to release a fire-extinguishing particulate / gaseous agent.

[0026] These condensation aerosol agents are particularly useful in difficult fires, such as lithium-ion battery fires, because the released agent has the ability to interrupt the fire's chemical chain reaction. This extinguishing mechanism significantly reduces the amount of agent required.

[0027] Furthermore, the fine size of the fire extinguishing particles results in a large surface area for the agent, allowing for very rapid reaction within the flame, making the aerosol agent very rapid at extinguishing the fire.

[0028] The panels, sheets, various forms and coverings are self-contained and an improvement over canister-type aerosol generators as they provide both fire detection and activation of condensed fire extinguishing sheets, panels, various forms and coverings, further improving the distribution of extinguishing agents within a shielded enclosure.

[0029] The invention comprises, in part, a fire suppression system for use in an enclosure for a fire hazard, the fire suppression system including a panel of condensation aerosol fire suppression material having a first enclosure-facing side and a second hazard-facing side, a fire-resistant material disposed proximate the first enclosure-facing side, and a sealant material disposed on the second hazard-facing side.

[0030] The panels can also be used "as is," i.e., without attachment to an enclosure, and without ceramic paints, adhesives, sealants, etc. For example, when packing a new battery or laptop computer for shipping on a truck or plane, the person doing the packing can insert a simple panel of solid aerosol into the shipping box without attaching it to the box. Such a panel may not require any adhesives, sealants, ceramics, etc.

[0031] In an embodiment of the invention, the fire suppression system further comprises an insulating layer disposed between opposing sides of the first enclosure and the fire resistant material.

[0032] In an embodiment of the invention, the fire resistant material comprises a ceramic paint.

[0033] In an embodiment of the invention, the panel further has at least one lateral side extending between the first enclosure-facing side and the second hazard-facing side. A fire resistant material may be disposed on the at least one lateral side.

[0034] In an embodiment of the invention, the fire suppression system further comprises an adhesive region disposed on the enclosure-facing side of the fire-resistant material. The adhesive region may include a layer of adhesive material disposed on the enclosure-facing side of the fire-resistant material and a removable layer of protective material covering the layer of adhesive material.

[0035] In an embodiment of the invention, a fire suppression system includes an aerosol material disposed on or in physical proximity to a potential fire hazard, the aerosol material configured to be activated by exposure to at least one of heat or flame, the aerosol material being in the form of at least one of: a body of material impregnated with an aerosol fire suppression substance; a coating applied to a surface of the potential fire hazard or in physical proximity to the potential fire hazard; In an embodiment of the invention, the body of material is one of flexible, rigid, or a combination thereof; has a shape that is one of cylindrical, pyramidal, prismatic, rectangular, spherical, irregular shell, or a combination thereof; is one of hollow, generally solid, generally solid but porous, or a combination thereof.

[0036] The panels may be provided for mounting on an enclosure or as dividers or dividers within an enclosure to separate sections of the hazardous material and / or may be mounted on or within the hazardous material, for example within a space within a battery module formed of multiple cells. In an embodiment of the invention, the dividers or dividers are used in shipping batteries or electrical devices in a box inside a larger box or package.

[0037] In an embodiment of the invention, the aerosol material is preferably similar in mechanical properties to plastics, so that structures or specific parts of the hazard can be made from the aerosol material. The aerosol material can be provided with the appropriate parts, formed, stamped, molded and machined to provide the necessary parts for the hazard, while being available as an extinguishing agent in case of fire. Thus, when the extinguishing agent is integrated into the hazard, an additional mechanism is provided to bring the extinguishing agent as close as possible to the hazard.

[0038] In an embodiment of the present invention, the aerosol fire suppression material includes at least one of potassium nitrate, potassium carbonate, epoxy resin, organic resin, dicyandiamide (DCDA), magnesium, and similar materials that constitute a fuel and an oxidizer. In a preferred embodiment of the present invention, the aerosol material does not include strontium in any form or composition due to concerns regarding potential adverse health effects.

[0039] In an embodiment of the invention, the aerosol material further comprises multiple layers of an aerosol fire suppression material, the multiple layers may include at least two layers, and further the aerosol fire suppression material of a first layer is different from the aerosol fire suppression material of a second layer.

[0040] In an embodiment of the invention, the fire suppression system further comprises an initiator operably coupled to the aerosol material to facilitate actuation of the aerosol fire suppression material.

[0041] In an embodiment of the invention, the fire suppression system further includes a fire detector operably coupled to the initiator to activate the initiator upon detecting at least one of heat above a predetermined temperature, flame, combustion products above a predetermined concentration, and combustion products having at least a predetermined composition.

[0042] In an embodiment of the present invention, the fire suppression system further comprises a controller coupled to the initiator and the aerosol material.

[0043] In an embodiment of the invention, the control device includes a manual actuator that allows the initiator to be selectively activated by a human.

[0044] In an embodiment of the invention, the fire suppression system further comprises a fire detector and a controller operatively coupled to the initiator for activating the initiator upon detection of at least one of heat above a predetermined temperature, flame, combustion products above a predetermined concentration, and combustion products having at least a predetermined composition. In an embodiment of the invention, the fire hazard comprises at least one of a device and a treatment system, and the controller is coupled to a monitoring device that monitors operation of the device. Such a device may be a battery or battery bank in a vehicle or facility. Alternatively, the treatment system may be any type of manufacturing or operating system where a fire hazard is particularly prominent.

[0045] In an embodiment of the invention, the aerosol material is in the form of a body of material impregnated with an aerosol fire suppression substance, and a layer of protective material is disposed on the side of the body of material that is placed against the fire hazard, the layer of protective material being disposed in a pattern such that a portion of the body of material impregnated with the aerosol fire suppression substance is exposed.

[0046] The foregoing and other features and advantages of the present invention will become more apparent from the following detailed description of the presently preferred embodiments, when read in conjunction with the accompanying drawings, which are not drawn to scale. The detailed description and drawings are merely illustrative of the invention rather than limiting, the scope of the invention being defined by the appended claims and equivalents thereof. [Brief description of the drawings]

[0047] [Figure 1] 1 is a schematic diagram illustrating a typical enclosure in which a potential fire hazard is located. [Diagram 2] FIG. 2 is a schematic diagram showing an aerosol product according to an embodiment of the present invention placed on the fire hazard enclosure shown in FIG. 1. [Diagram 3] FIG. 2 is a schematic diagram illustrating an alternative embodiment of the present invention showing an alternative configuration of the aerosol product. [Figure 4] 1A-1C are schematic diagrams illustrating alternative embodiments of the present invention showing layers or arrangements of aerosol products of different shapes. [Diagram 5] 1 is a schematic diagram illustrating an alternative embodiment of the present invention showing the placement of an aerosol agent in an enclosure and further illustrating an exemplary control, detection and initiation system. [Figure 6] FIG. 1 is a schematic diagram illustrating an embodiment of the present invention showing a particular aerosol panel configuration. [Figure 7] FIG. 1 is a schematic diagram illustrating an embodiment of the present invention showing a particular aerosol panel configuration. [Figure 8] FIG. 1 is a schematic diagram illustrating an embodiment of the present invention showing placement of an aerosol system over a fire hazard within an enclosure. [Figure 9] FIG. 1 is a schematic diagram illustrating an embodiment of the present invention showing the mode in which an aerosol material may be applied to a fire hazard. [Figure 10] FIG. 1 is a schematic diagram illustrating an embodiment of the present invention in which an aerosol material is incorporated into a fire hazard. [Figure 11] FIG. 1 is a schematic diagram of an embodiment of the present invention showing the placement of an aerosol material onto an exemplary fire hazard, such as an individual battery cell. [Figure 12] FIG. 1 is a schematic diagram of an embodiment of the present invention showing the placement of aerosol material onto an exemplary fire hazard, such as grouped individual battery cells. [Figure 13] FIG. 1 is a schematic diagram of an embodiment of the present invention showing the placement of aerosol material within interstitial spaces between units of an exemplary fire hazard, such as a string of individual battery cells. [Figure 14] FIG. 1 is a schematic diagram of an embodiment of the present invention showing the placement of aerosol material within interstitial spaces between units of an exemplary fire hazard, such as an array of individual battery cells. [Figure 15] 1 is a series of diagrams illustrating an embodiment of the present invention in which the aerosol material is incorporated into a divider or partition. [Figure 16] FIG. 2 is a cross-sectional view of an enclosure made from hardened aerosol material according to an embodiment of the present invention. [Figure 17] FIG. 1 is a perspective view of an aerosol panel incorporating suppressive coatings selectively positioned to control activation of aerosol material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] While the invention may be embodied in many different forms, specific embodiments have been shown in the drawings and are described in detail herein, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment or embodiments illustrated.

[0049] In order to enable those skilled in the art to practice the invention, the present invention and the accompanying drawings are described with reference to the indicated reference numbers. The drawings and description are illustrative of various aspects of the present invention and are not intended to narrow the scope of the appended claims. Unless otherwise stated, the terms and phrases in the specification and claims are intended to convey their plain, ordinary and customary meaning to those skilled in the applicable art. It should be noted that the inventor may be his own lexicologist. The inventor, as his own lexicologist, has expressly chosen to use only the plain and ordinary meaning of a term in the specification and claims unless expressly stated otherwise, and further expressly states a "special" definition of the term to explain how the definition differs from the plain and ordinary meaning. It is the inventor's intention and desire that the plain, plain and ordinary meaning of the term be applied to the interpretation of the specification and claims, unless expressly stated to apply a "special" definition.

[0050] The inventors further recognize the normal rules of English grammar. Thus, where a noun, term or phrase is intended to be further characterized, specified or narrowed in any way, such noun, term or phrase expressly includes additional adjectives, descriptors or other modifiers in accordance with the normal rules of English grammar. In the absence of such adjectives, descriptors or modifiers, such noun, term or phrase is intended to convey its plain and ordinary English meaning to one of ordinary skill in the applicable art, as set forth above.

[0051] Moreover, the inventor is fully informed of the standards and application of the special provisions of 35 U.S.C. 112(f) or former 35 U.S.C. 112-6. Thus, the use of the words "function," "means," or "step" in the detailed description of the invention or in the claims does not in any way indicate an attempt to invoke the special provisions of 35 U.S.C. 112(f) or former 35 U.S.C. 112-6 to define the invention. On the contrary, if an attempt is made to invoke the provisions of 35 U.S.C. 112(f) or former 35 U.S.C. 112-6 to define the invention, the claims would specifically and clearly recite the precise phrase "means for" or "step for" and the specific function (e.g., "means for roasting") without reciting any structure, material, or act in support of the function in such phrase. Thus, even if a claim recites a "means for" or "steps for," the inventor clearly does not intend to invoke 35 U.S.C. 112(f) or former 35 U.S.C. 112-6 if the claim further recites any structure, material, or act that supports the means or step or performs the recited function. Moreover, even if the claim recites 35 U.S.C. 112(f) or former 35 U.S.C. 112-6 to define the claimed invention, the invention is not limited to only the specific structures, materials, or acts described in the illustrated embodiment, but is further intended to include any and all structures, materials, or acts that perform the claimed function as described in alternative embodiments or configurations of the invention, or that are equivalent structures, materials, or acts now known or developed in the future to perform the claimed function.

[0052] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of various aspects of the invention. However, those skilled in the relevant art will understand that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or described more generally in order to avoid obscuring the invention. In many cases, a description of the operations will be sufficient to enable the implementation of various forms of the invention, particularly when the operations are performed in software.

[0053] It should be noted that there are many different alternative configurations, devices and techniques to which the disclosed invention may be applied, and therefore the full scope of the invention is not limited to the following examples.

[0054] Various aspects of the present invention may be described in terms of functional block elements and various processing steps. Such functional blocks may be realized by any number of hardware or software components configured to perform the specified functions to achieve various results.

[0055] Thus, although improved devices, systems and methods for carrying out the production and dispersion of pyrotechnically generated fire suppression materials have been disclosed, it will be understood that references to systems and devices in the following disclosure are also applicable to other fire suppression devices and methods of fire suppression that utilize the associated structures for the processes described. Similarly, references to methods are also applicable to systems and devices that perform processes with the operation of the described devices. It will be recognized that many modifications may be made to the present invention without departing from the scope of the claims, including, but not limited to, combinations of elements or structures of the various embodiments shown. For example, although specific materials and / or methods of manufacturing the devices described herein may be described, it will be understood that one skilled in the art may select different materials and / or manufacturing methods as desired or necessary to meet the requirements of a particular application without departing from the scope of the present invention.

[0056] 1-7, for example, illustrate embodiments of the present invention in which a pyrotechnic aerosol fire suppressant that can be released by exposure to heat and / or flame is provided in the form of a body of material impregnated with the pyrotechnic aerosol agent, in embodiments in the form of a sheet. Such sheets may be strategically placed on or near potential fire hazards. Aerosol agent panels (sheets, coverings, etc.) are particularly suitable when space for other aerosol extinguishing systems is limited or when there are significant obstacles to the distribution of the aerosol agent. Alternatively, aerosol agent sheets or coverings may be provided as a supplement to the pyrotechnic fire suppressant that is distributed via a nozzle.

[0057] Although the material impregnated with the fire suppressant is described and illustrated herein in the form of a sheet, other geometric configurations are also possible and are considered to be within the scope of the present invention. Such alternative configurations of the impregnated body of material may include, but are not limited to, flexible, rigid, one of a combination thereof; a shape that is cylindrical, pyramidal, prismatic, rectangular, spherical, irregular shell, one of a combination thereof; hollow, one of a solid throughout, one of a solid throughout but porous; and combinations thereof. Also, for purposes of this disclosure, references to "aerosol material" are meant to refer to a material and / or mixture or composition of materials that are embedded or impregnated into a binder material, including but not limited to an epoxy resin material. The general operation of the aerosol fire suppressant is as follows. a) The condensate (before it is ignited) is usually a solid material (but can be a liquid or slurry) composed primarily of fuel (which can be an epoxy resin) and an oxidizer (such as potassium nitrate). This condensate is similar to other pyrotechnic materials, which can include fireworks, ammunition, airbag inflators, etc. b) Once the material is ignited, the oxidizer will greatly accelerate the combustion. The burn rate will determine whether the extinguishing agent will develop within a few seconds or whether the bomb will burn instantly to produce its explosive effect. c) The combustion of the condensate generates the extinguishing aerosol agent. Typically, the solid pellets generate the actual aerosol in the form of ultra-fine particles (which may usually be present as white smoke) along with several gaseous by-products which may include nitrogen and other gases. d) In a typical fire, the burning fuel creates chemical radicals that combine with oxygen in the air, creating an exothermic reaction that sustains combustion. e) The subject fire will continue to burn unless one or more of the following events occur: 1. Oxygen is removed (e.g., a CO2 fire extinguisher is used) 2. The fire is cooled (water sprinklers or water hoses are used) 3. Fuel is removed (a gas injection fire from a leaking pipe will stop when the fuel supply valve is closed) f) Pyrotechnic aerosol fire suppression systems do not use any of the three "traditional" methods mentioned above. The particulates generated by the aerosol fire suppression agent are potassium-based. When the very fine particulates enter the flames of the target fire, the fuel radicals that would normally bind to oxygen preferentially bind instead to the potassium radicals provided by the aerosol agent. The new compounds generated via the potassium radicals are stable and will not burn, so the target fire is extinguished. g) Again, there is still oxygen present from the room that normally surrounds the fire and is necessary to allow the target fire to continue to burn. Pyrotechnic aerosol fire suppressants do not reduce the oxygen available to the fire. Instead, the fuel radicals of the target fire have a higher affinity for the potassium radicals produced by the pyrotechnic than for the oxygen in the surrounding atmosphere. Thus, while oxygen is still present, the target fire is extinguished as the oxygen is displaced by the presence of potassium.

[0058] 1 is a schematic diagram showing a typical enclosure 10 in which a potential fire hazard 12 is located. The hazard to be protected may comprise, for example, a container, which may be substantially leak-proof or may have minor leaks, and may represent a potential fire hazard. The fire hazard is within the enclosure. The class of fire may be Class A (normally combustible), Class B (flammable liquids), Class C (electrical fires), Class D (flammable metals such as lithium), or materials that do not require atmospheric oxygen to burn, such as certain electrolytes in lithium-ion batteries.

[0059] 2 is a schematic diagram showing an aerosol product 14 according to an embodiment of the present invention disposed on the fire hazard 12 shown in FIG. 1. Aerosol agents formed from sheets, panels or other shapes may be fitted within the enclosure 10. The amount and placement of the aerosol agent will depend on the volume, available space, leaks, and obstructions. In high energy hazards, an unwanted fire will have enough energy, flame and / or heat to initiate combustion of the aerosol agent. In this simplest arrangement, there is no requirement for fire detection and activation of the fire suppression function is automatic.

[0060] The formulation of the agent of the "solid aerosol-forming compound" is an energetic material. The energetic material is usually composed of a fuel and an oxidizer. The burning rate is determined by the choice of materials. Very rapid burning is considered explosive. Slow burning formulations are used by fire protection manufacturers of solid aerosol-forming compounds. Considering solid aerosol-forming compounds, the fuel used is usually epoxy resin and the oxidizer is usually potassium nitrate or a similar oxidizer. More fully described, typical materials that may be used in the composition of the aerosol pellets (used in pyrotechnic generators) or on the impregnated sheets include, but are not limited to, one or more of potassium nitrate, potassium carbonate, epoxy resin, organic resin, dicyandiamide (DCDA), magnesium. Between potassium nitrate and potassium carbonate, potassium carbonate is a strong oxidizer, but potassium carbonate is sensitive to shock, so potassium nitrate is considered to be safer and more stable. Therefore, for the purposes of the present invention, potassium nitrate is considered to be a safer material to implement in or adjacent to fire hazards, especially those that may be sensitive to movement, shock, vibration, etc.

[0061] When constructing a pyrotechnic generator or impregnated sheet, various factors may be considered in determining the rate of fire suppression aerosol production, including, but not limited to, the specific chemical composition; the surface area of ​​the sheet, or the nozzle area and / or chamber volume in the case of a generator, or the shape and / or thickness of the sheet or panel; the use of a suppression coating (on the sheet, panel or generator pellets), such as a ceramic "paint".

[0062] Additionally, in embodiments of the invention where a significant amount of epoxy resin is used to provide a self-supporting body for the aerosol-generating material rather than relying on an external frame or holder to support the aerosol-generating material, the epoxy resin may affect the burn rate, potentially slowing the burn to the point of self-extinguishing. Thus, a burn-modifying or burn-promoting material, such as, for example, powdered or flaked magnesium, aluminum, or similar materials, may be dispersed within the resin.

[0063] FIG. 3 is a schematic diagram of an alternative embodiment of the present invention in which an aerosol product 14 is placed over a container, enclosure, enclosure, etc. 10 containing a hazardous material 12 .

[0064] FIG. 4 is a schematic diagram showing an alternative embodiment of the present invention, illustrating an alternative arrangement of the aerosol product 14, i.e., illustrated as multiple layers 16, 18. Additional layers may be provided if desired. For example, forms into which the aerosol product may be incorporated include panels, sheets, blocks, strips, and rods. The aerosol agents of the aerosol product 14 may be placed in optimal locations on the enclosure 10 and fire hazard 12. Upon initiation, all aerosol agents are activated by the energy of the aerosol material. Even if the attached sheets / panels or forms of aerosol agents do not contact each other, nearby aerosol agents will begin to burn and generate fire extinguishing agents. Alternatively or additionally, the layers 16, 18 may be made using different aerosol materials to be deployed at different temperatures to suit the nature of the particular fire hazard 12 in question.

[0065] 5 is a schematic diagram illustrating an alternative embodiment of the present invention showing the placement of an aerosol product 14 in combination with a detection system and an actuation system. In addition to self-initiation in the event of significant flame or energy from a fire, the aerosol material can be initiated by adding one or more fire detectors 22 and an electrical initiator 24 for use when a fire is not expected to have the energy required to initiate aerosol combustion or when more reliability is desired. Fire detection can use smoke detectors, heat detectors, flame detectors, and / or one or more automatic or manual actuation control stations 20.

[0066] In addition to or instead of using a fire detection system to activate the fire suppression aerosol generator or sheet, activation can also be triggered by a signal received from a process monitoring system (not shown) provided to monitor equipment that may potentially catch fire. For example, in the case of protecting a battery compartment in a vehicle, in addition to a dedicated fire / smoke sensor configured to send a signal to a control device, the battery bank can also have a monitoring system that can detect malfunctions in the battery bank that could cause a fire or explosion, but can respond to situations before there is actually detectable smoke, excessive heat or flame.

[0067] These panels, forms or coverings 14 may be applied to the ceiling / top, walls and floor / bottom of an enclosure 10, such as, but not limited to, a battery enclosure, to disperse the agent directly into the enclosure / room upon ignition. In cases where the enclosure is one with active ventilation (e.g., a blower) that does not or cannot be shut off during a smoke or fire event, or in situations where the openings are fixed (such as ventilation louvers), or where the integrity of the enclosure may be rapidly compromised by a smoke / heat / fire event, one of ordinary skill in the art using routine design and engineering techniques may increase the amount of aerosol agent to account for potential loss or misdirection of activated aerosol material that may result from such compromises.

[0068] The combustion of the aerosol agent to generate the extinguishing aerosol can be initiated directly by the intense heat of the flame or fire. It is further possible for the combustion of the aerosol agent to be initiated by various fire detection systems 20, 22, 24 using heat, smoke or flame sensors or manual activation stations to electrically activate an initiator adapted to the aerosol agent. Other types of initiators are thermally activated or mechanical types using an increase in temperature within the compartment, or manual mechanical means to activate the initiator.

[0069] 6-7 show further details of the condensation aerosol within the sheets, panels and coverings.

[0070] As shown in Figures 6-7, several improvements and features can be provided to make the ribbed or flexible condensation aerosol panels, sheets and coverings more practical.

[0071] A thin ceramic paint or coating 30 or similar fire retardant may be applied to selected surfaces 32 of the panels, sheets and / or aerosol coatings 26 that are applied to one or more surfaces 34 of an enclosure 36 that surrounds or contains a fire hazard (not shown). Such materials may be capable of withstanding temperatures of 1500 degrees Fahrenheit or higher for a period of time. These coatings limit the burning of the panels, sheets and coatings to areas where the fire retardant material is not applied. This allows for improved control of how and where the aerosol material burns to generate fire extinguishing agents and further prevents burning too quickly. Burning too quickly or uncontrolled can generate excessive pressure that can damage the enclosure of the hazard. Ceramic coatings are typically considered to be similar to a very thin paint layer, but the specific thickness may be determined by one skilled in the art to accommodate specific implementation requirements. At the time of this writing, there are many brands and products in the industry that are potential candidates for ceramic coatings that may be implemented in accordance with the present disclosure. Some ceramic paints or coatings can withstand very high heat. This property can be used to selectively control or limit the surface area of ​​a solid aerosol that will ignite and burn. In an embodiment of the invention, the ceramic paint thickness for typical applications is between 1 mil (0.001 in.) and 6 mils. The ceramic coating thickness is between 6 mils and 50 mils. One product available commercially at the time of this writing is the Cerakote™ C series of coatings, such as C-7700, which is nominally rated up to 1,800°F (1,000°C). Another brand of product is the 3M™ NEXTEL™ paints and coatings.

[0072] A sealant, rubberized coating or film 38 may be applied to the surface of the aerosol material to prevent the harmful effects of moisture or other corrosive chemicals that may be present in the area of ​​the condensed aerosol material. The advantage of this is that the aerosol material is protected from environmental contamination that may degrade the agent material and reduce performance. These added sealants, rubberized coatings or films are flammable and therefore do not prevent the aerosol material from reacting to flame or heat, and a flame from a hazardous material will instantly burn through the sealant, rubberized coating or film to still rapidly activate and extinguish the condensed aerosol material. Furthermore, it is well known to mix the sealant with an energetic material that will start to burn faster than the aerosol agent, as the sealant not only protects the solid aerosol agent but also helps improve the panel's response time to an exposed flame. The thickness of the sealant may likewise be modified by those skilled in the art according to the specific implementation requirements. In an embodiment of the present invention, a thin coating of 10 mils (where 1 mil is 0.001 inches) to 100 mils is considered to be a preferred range in an embodiment of the present invention. A known potential candidate is a rubber sealant sold under the brand name FLEX-SEAL™ or a similar product from 3M™.

[0073] Insulation 40 may be added to the aerosol material to limit heat transfer from the burning aerosol material to the enclosure or packaging. High performance insulating materials such as ceramic insulating sheets, fabrics or coverings may be used. The advantage of this is that the enclosure or packaging may be thinner or made of less expensive materials and may be combustible such as fiberglass, plastic, fiberboard or cardboard containers.

[0074] One source of insulating material deemed suitable for use in accordance with embodiments of the present invention is 3M™, which manufactures a leading line of high performance insulating products known as 3M™ NEXTEL™. In accordance with embodiments of the present invention, the insulating layer is provided as a thin fabric or material made with construction and performance characteristics similar to flexible cardboard. This material has previously been used in aerosol canisters to slow heat loss after release to prevent damage, but has not been used to directly prevent the transfer of heat from the aerosol to the enclosure.

[0075] A wide range of high performance ceramic insulation products are available to withstand thermal conduction. Certain models of 3M's NEXTEL™ or INTERAM™ products are considered rated above 850°C and are available as solid structural sheets or non-structural woven fabrics.

[0076] When the panels or other features are to be attached to an enclosure or hazard, a spray or brush adhesive may be applied during installation.

[0077] Alternatively, adhesive 42 may be added to the back of the aerosol material of the panels, sheets and coverings before installation. The advantage of this is that the adhesive may be pre-applied, so that the adhesive is exposed when the film used for packaging is removed, and the panels, sheets and coverings may then be attached more quickly and with less effort. For example, a layer of adhesive may be applied and then covered by a removable protective film or peel layer (not shown). Examples include double-sided mounting tape, or a layer of adhesive pre-applied to the side of the aerosol material and covered by a protective layer or strip that is selectively removed. Those skilled in the art will select an adhesive suitable for the specific mounting conditions, but adhesive materials sold by 3M™ or other common adhesives such as Gorilla Glue™ are considered suitable for many applications. One reason for selection is that the adhesive chemistry must be compatible with the chemistry of the aerosol fuel and oxidizer, such that the combustion of the adhesive material does not interfere with the fire suppression properties of the aerosol, is not toxic in high heat or flame environments, etc.

[0078] 8-14 show several different applications of aerosol sheets, panels and coverings. The condensed aerosol agent in the sheets, panels and coverings 54 is Within the enclosure 50, either by mounting on the interior or exterior surface of the enclosure itself, or on or as a partition within the interior of the enclosure. On the hazardous parts 52 themselves, including the parts within the enclosure, In the hazardous parts (Figure 10), or To configure the structure of dangerous parts It may be provided completely or partially.

[0079] In addition to the condensation aerosol fire extinguishing sheets, panels or coverings being applied to enclosures, boxes or similar containers, or used as dividers or separators within enclosures, the condensation aerosol materials may be used in the immediate vicinity of, on or within hazardous materials or assemblies.

[0080] The aerosol material in panels, flexible and / or rigid sheets, and coverings may be applied directly onto the fire hazard or in close proximity to the fire hazard. Figure 9 shows an example of how one or more sheets 54 of aerosol material may be applied to one or more sides 56 of a hazard 52.

[0081] The condensation aerosol material may be applied to one or more surfaces of the hazardous material, on or in the immediate vicinity of such surfaces, or the hazardous material may be provided such that it is partially or completely covered or surrounded by the aerosol material within a panel, flexible and / or rigid sheet or covering.

[0082] The advantage of this is that the time required for detection of a fire and activation of the aerosol fire-extinguishing material can be significantly reduced. Additionally, the extinguishing agent is dispersed closer to the fire hazard.

[0083] An example would be one or more lithium ion battery modules within a larger enclosure, or a complete battery pack. The modules can be protected together as a single assembly, or each module can be protected individually.

[0084] Additionally, for added assurance, it is further possible for a larger enclosure containing a battery module, battery pack or battery cell 60 (FIGS. 11-14) to provide aerosol protection using its own aerosol material within a panel, sheet or covering.

[0085] In embodiments of the invention, aerosol material may be applied within a hazardous material by placing a coating 58 over a component of the hazardous material (as shown in FIGS. 11-12) or by filling some or all of the voids in the hazardous material with aerosol material 62 (as shown in FIGS. 13-14). With particular reference to FIG. 11, embodiments of the invention include a method of protecting a potential fire hazard by applying an aerosol-generating material directly to the exterior surface of a structure or device that constitutes the actual hazardous material. For example, the aerosol material may be applied directly to the exterior surface of an individual battery cell prior to incorporation into an overall battery pack that holds one or more individual battery cells. The aerosol material may be applied by spraying, dipping, application of a thin sheet of the aerosol material, for example through an intervening layer of adhesive, or a combination of two or more of these procedures.

[0086] 15 is a series of diagrams illustrating an embodiment of the invention in which the aerosol material is incorporated into a divider or partition. Specifically, divider 70 is made as a series of panels 72 that may be integrally formed as one unit, for example by molding. Alternatively, divider 70 may be made from separate panels 72 adhesively attached to one another. In another alternative embodiment, divider 70 may be made from one elongated large panel 72 and a series of smaller panels 72, all suitably molded or stamped with slots (not shown) to facilitate the larger and smaller panels fitting together to form the divider.

[0087] 16 is a cross-sectional view of an exemplary fire hazard 80 in the form of multiple batteries 82 contained within a case 84. The batteries 82 may be contained within the case 84 for transport or storage. Alternatively, the case 84 may be used to form a functional unit in which multiple batteries 82 are held together and electrically coupled to one another. In an embodiment of the invention, the case 84 has four sides 86 (two of which are shown), a bottom 88 and a top plate 90, which may be held together by fasteners 92, 94, such as screws received in threaded holes (shown but not numbered).

[0088] In the embodiment of FIG. 16, one or more of the sides 86, bottom 88 and top plate 90 may be made from a hardened aerosol material as described herein. They may be machined to specific dimensions or molded, stamped, rolled, or made in any suitable manner. Additionally, making the structural components of the battery pack or power source from a reinforced resin aerosol material allows the top, bottom, side walls, and / or internal dividers or walls to be machined, tapped for screws, or drilled for other fasteners. Because the aerosol materials contemplated by the present invention are self-activating in the presence of a sufficiently high temperature and / or active open flame, the use of such materials in constructing the internal structural elements of the enclosure and potential fire hazard may eliminate the need for sensors, advanced processors, and / or ignition devices to ignite the aerosol-generating material and release one or more aerosol fire suppression substances. There is no need to modify the shape and configuration of the enclosure and / or internal structural elements.

[0089] FIG. 17 is a perspective view showing an aerosol panel 100 having a suppressive coating 104 on which a base layer 102 of aerosol impregnated resin is selectively disposed to control activation of aerosol material.

[0090] To control further combustion and prevent the entire surface area of ​​the panel, sheet or covering from starting to ignite too quickly, a portion of the surface of the panel, sheet or covering 102 may be painted / coated with a retardant, such as a ceramic paint 104. This retardant coating 102 may be in the form of a checkerboard or similar pattern of ceramic paint 104 silk screened onto the panel, sheet or covering 102, thus limiting the speed at which the panel will activate when a large area of ​​the panel is exposed to flames. This ensures controlled activation of the panel rather than uncontrolled rapid activation (which could result in an explosion in the worst case scenario). In addition to the checkerboard pattern shown in FIG. 17, alternative patterns may include stripes or stripes, swirl patterns, diamond patterns, concentric circles (similar to the central circle of a target), etc. One function of the pattern of protective material that covers some of the aerosol material and exposes others is to ensure that not all of the aerosol material is immediately involved in the fire, thus allowing the aerosol material to be released gradually or at least in a controlled manner over time, for example over a minute or more, if desired or as needed to meet particular implementation requirements.

[0091] The agent material may be applied to the parts as a sheet or coating prior to fabrication into a finished assembly, or the assembly can be sprayed or dipped with the aerosol material.

[0092] Furthermore, it is possible to completely or partially fill or impregnate voids in the assembly with the aerosol material by injecting the aerosol material into or around the assembly, some space may be left for ventilation of the assembly.

[0093] The battery module may contain the aerosol agent as a grid within the battery module so that sufficient aerosol agent is provided but some space may be left for ventilation of the assembly.

[0094] In an embodiment of the invention, the aerosol material may be applied within the hazardous area by completely or partially covering parts of the module or completely or partially covering the battery cells, some space may be left for ventilation of the assembly.

[0095] In an embodiment of the invention, the fire hazard structure itself may be made from a condensed aerosol. For example, the aerosol may be formed into ridges with an appearance and physical properties similar to a material such as hard plastic. This material may be machined, stamped, molded, or otherwise formed, so that the structure of the battery module may be formed from the aerosol instead of metal or plastic.

[0096] Further details and improvements of aerosol panels, sheets and coverings are described in the above paragraphs. The same improvements, such as ceramic coverings, sealants, insulators and adhesives, can be employed when providing condensed aerosol materials near, on or within hazardous parts or assemblies.

[0097] The aerosol releasing fire suppression system disclosed herein is believed to offer various advantages over known systems.

[0098] A. Compared with other more conventional fire extinguishing methods, the advantages of the present invention are:

[0099] Battery fires involving thermal runaway are extremely difficult to prevent until the fire is extinguished and the danger of thermal runaway is eliminated. Embodiments of the present invention extinguish fires and stop thermal runaway very quickly in lithium ion battery applications, whereas conventional agents (dry chemicals, standard water systems, foam, carbon dioxide, etc.) typically fail to achieve extinguishment. This superior performance is achieved because the extinguishing mechanism of aerosol agents is the interruption of the fire's chemical reaction.

[0100] In addition to their performance against battery fires, embodiments of the present invention extinguish other types of fires other than battery fires much faster than most other agents.

[0101] Embodiments of the present invention are self-contained and are considered to be much lower in cost and weight compared to other extinguishing agents.

[0102] B. Several perceived advantages of the present invention compared to other aerosol systems that use canisters can be described as follows:

[0103] Battery fires and thermal runaway can progress very quickly. Time to detect, act and extinguish these fire events is critical. Embodiments of the present invention provide faster response in Li-ion battery applications for the following reasons:

[0104] The use of aerosols on panels, sheets and other assemblies can bring them much closer to fire when placed inside an enclosure, or directly over a hazard where ignition is anticipated, or when placed inside a battery assembly, or when used as a covering for an actual battery.

[0105] By spreading the aerosol-generating agent over a sheet or panel, the barrier is overcome by essentially improving the distribution of the agent.

[0106] The much faster speed of action means that the aerosol is released into a smaller, and therefore less dangerous, fire with less heat inside the battery, so the task of extinguishing the fire and stopping thermal runaway becomes easier the sooner the agent is applied.

[0107] Embodiments of the present invention can provide a high safety margin to overcome enclosure damage, leaks, or to compensate for ventilation systems that may not be turned off. The amount of agent provided to the panel can be easily increased.

[0108] Embodiments of the present invention are self-contained, low cost, have very low space requirements, are very lightweight and are virtually maintenance free.

[0109] The present invention has a higher level of reliability since no fire detection or activation systems are required and with less equipment there is less risk of failure.

[0110] C. Compared to other aerosol systems that use small units of exposed aerosol in small frames, the advantages of the present invention are:

[0111] The present invention does not require a frame or retaining assembly as the agent may be adhered to the enclosure, mounted on or impregnated into the hazardous material, or applied as a coating. Additionally, the agent may be machined or formed to provide a fabricated element of the hazardous material.

[0112] The size and shape of the components of the present invention can be tailored to each application. The present invention provides a much higher level of flexibility in installation.

[0113] The present invention is much faster to activate and extinguish the fire, and it is especially important to extinguish the fire quickly before it spreads and makes thermal runaway even more difficult. Seconds of response time become crucial.

[0114] The high safety margin inherent in the present invention makes it possible to overcome the leakage of the aerosol agent and continue protection by preventing re-ignition of the fire until the remains of the battery have cooled, ending the risk of thermal runaway.

[0115] Compared to these smaller frame mounted units, the present invention offers greater installation flexibility, significantly faster activation and extinguishing times, improved agent dispersion, the ability to overcome difficult obstacles, reduced cost, lighter weight / space savings, and no maintenance.

[0116] Although the embodiments of the invention disclosed herein are presently considered to be preferred, various modifications and adjustments can be made without departing from the spirit or scope of the invention. The scope of the invention is set forth in the appended claims, and all modifications and adjustments that come within the meaning and range of equivalents are intended to be embraced therein. For example, although the present disclosure may focus on the use of products, systems and methods in the environment of battery fire hazards, particularly lithium ion battery fire hazards, it will be understood that the scope of the invention is not so limited and that the principles described and illustrated herein may be applied to other types of fire hazards.

[0117] Although the invention has been described with reference to the above examples, it will be understood that many adjustments and modifications are deemed to be within the true spirit and scope of the embodiments of the invention as disclosed herein. Many modifications and other embodiments of the invention described herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the invention is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms have been employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0118] This application claims priority to U.S. Patent No. 17 / 389,539, filed July 30, 2021, the entire contents of which are expressly incorporated herein by reference.

Claims

1. A surrounding body that defines the interior, and A divider that divides the interior into at least two separate spaces It comprises one or more of the following: A fire suppression system in which at least a portion of the enclosure and one or more of the divisions are made from a mixture of an aerosol material and a flammable material configured to act to suppress a fire by being exposed to at least one of heat or flame.

2. The fire suppression system according to claim 1, wherein the flammable material is an epoxy resin.

3. The fire suppression system according to claim 1, wherein at least a portion of the surrounding body is made from the mixture.

4. The fire suppression system according to claim 1, wherein the divided body is made from the mixture.

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