Fire containment device with self-closing blowout panel

Abstract

A fire containment device includes a housing and a blowout panel. The housing includes an interior airspace and an opening. The housing is configured to store a battery. The blowout panel is transitionable between a closed state, in which the panel obstructs the opening to prevent fluid communication between the airspace and an ambient environment, and an open state, in which the panel permits fluid communication between the airspace and the ambient environment via the opening. The panel is based towards the closed state with a bias force. The panel transitions from closed to open when a pressure in the airspace is sufficient to overcome the bias force. The panel remains open while the pressure in the housing remains sufficient to overcome the bias force. The panel transitions from open to closed when the pressure in the airspace is no longer sufficient to overcome the bias force.

Description

FIRE CONTAINMENT DEVICE WITH SELF-CLOSING BLOWOUT PANELCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 598,986, filed November 15, 2023, the contents of which are incorporated by reference herein in their entirety.BACKGROUND

[0002] Small scale, portable electronic devices are increasingly being powered by rechargeable batteries. With the advent of higher performing and more affordable lithium ion batteries, this type of power source and recharge capacity is also becoming increasingly available for larger commercial, industrial and personal use vehicles and equipment. Unfortunately, as larger and more energy dense batteries are developed to meet these application needs, the risk of thermal runaway correspondingly increases as well. Thus, the risk of individual battery failure due to thermal runaway increases. This risk may extend to the risk of migrating to other surrounding batteries during storage, transport and use. Once more, this risk is not limited to battery failure but may extend to an explosion with a toxic gas release and / or fire hazard depending on the chemistry, size and other factors of the battery makeup. These types of hazards may be faced by users in a moving car, operators of transportation cargo, and the public at large on roadways or other public areas. In today’s world, severe injury and fatalities are often the result of thermal runaway from just these types of situations.

[0003] Aspects of the present invention are directed to these and other problems.SUMMARY

[0004] According to an aspect of the present invention, a fire containment device includes a housing and a blowout panel. The housing includes an interior housing airspace and a housing opening. The housing is configured to store a battery such that the battery is exposed to the housing airspace. The blowout panel is disposed relative to the housing opening and transitionable between a closed state, in which the blowout panel obstructs the housing opening to prevent fluid communication between the housing airspace and an ambient environment, and an open state, inwhich the blowout panel permits fluid communication between the housing airspace and the ambient environment via the housing opening. The blowout panel is biased toward the closed state with a bias force. The blowout panel transitions from the closed state to the open state when a pressure in the housing airspace is sufficient to overcome the bias force. The blowout panel remains in the open state while the pressure in the housing remains sufficient to overcome the bias force. The blowout panel transitions from the open state to the closed state when the pressure in the housing airspace is no longer sufficient to overcome the bias force.

[0005] According to another aspect of the present invention, a method of modulating pressure in a fire containment device includes the following steps: positioning a battery in a housing having a pressure below a predetermined target; maintaining a panel of the housing closed with the pressure below the predetermined target; opening the panel of the housing upon the pressure reaching at least the predetermined target; and reclosing the panel upon the pressure returning to a level below the predetermined target.

[0006] In addition to, or as an alternative to, one or more of the features described above, further aspects of the present invention can include one or more of the following features, individually or in combination:- the battery is a lithium-ion battery;- the blowout panel transitions from the closed state to the open state when the pressure in the housing airspace is greater than 5 PSI;- the fire containment device further includes a biaser configured to supply the biasing force to the blowout panel;- the opening of the blowout panel facilitates at least one of toxic gas removal and heat removal from the airspace; and- the reclosing facilitates at least one of reducing oxygen supply to any fire in the airspace and reducing toxic gas release from the airspace.

[0007] These and other aspects of the present invention will become apparent in light of the drawings and detailed description provided below.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Fig. 1 is a side sectional view of an embodiment of a fire containment device with a repeatably usable blowout panel in a closed state.

[0009] Fig. 2 is a side sectional view of the fire containment device of Fig. 1 in an open state.

[0010] Fig. 3 is a chart depicting pressure within an embodiment of a fire containment device as described herein.DETAILED DESCRIPTION

[0011] Referring now to Figs. 1 and 2, a side sectional view of an embodiment of a fire containment device 100 is shown. The device 100 includes a body 110 that defines an airspace 125 and includes an opening 175. The device 100 is configured for holding and storing at least one power source 150 (hereinafter a “battery 150”), such as a lithium-ion battery made up of a plurality of individual battery cells 155, or another type of high-density, rechargeable battery. During storage of the battery 150 in the device 100 (i.e., when the battery 150 is not being used for powering any electronic device), the battery 150 may be prone to overheating, suddenly sparking and / or beginning a chain reaction process that might lead to thermal runaway, from battery cell 155 to battery cell 155 or, depending on packaging and arrangement, from one battery 150 to another battery 150 stored in the device 100. Such events can involve the release of gas 135 (e.g., electrolyte vapors) from the battery 150 into the airspace 125 of the device 100, which in turn increases the pressure in the airspace 125 above a nominal pressure (i.e., a desired pressure of the airspace 125). During such events (hereinafter “off-gas events”), the gas 135 can be released from the battery 150 in a chaotic and unpredictable manner, such that the gas 135 exits the battery 150 in the form of a non-continuous flow (e.g. , a flow including bursts and intermittent pauses) that increases the pressure in the airspace 125 in a non-continuous manner. Therefore, the device 100 includes a blowout panel 190 that is repeatably transitionable between opened (Fig. 1) and closed (Fig. 2) to maintain pressure in the airspace 125 below a predetermined threshold pressure during any such off-gas events. The predetermined threshold pressure has a magnitude above the nominal pressure of the device 100 but below a burst pressure at which the structural integrity of the device 100 will fail. In the closed position (FIG. 2), the panel 190 blocks the opening 175 to prevent fluid communication between the airspace 125 and an ambient environment 126. The panel 190 thereby traps potentially toxic gases, contains heat and isolates the airspace 125 to avoid influx ofoxygen from the ambient environment 126 for fueling fire. In the open position (FIG. 2), the panel 190 permits fluid communication between the airspace 125 and the ambient environment 126. The panel 190 thereby allows a pressure release in the event of an off-gas event. In this way, the integrity of the device 100 may be maintained.

[0012] In some embodiments, the panel 190 is in the form of a cover or a lid and the device 100 includes a biasing mechanism 160 that biases the panel 190 to the closed state (Fig. 1) with a bias force. In some embodiments, the device 100 includes a hinge for reversibly supporting opening and closing of the panel 190 in relation to the opening 175 and the airspace 125. With fire containment in mind, the panel 190 may present a face or underside to the airspace 125 of aluminum or other suitable safety conscious construction. Thus, while serving a blowout function by opening as needed, the panel 190 also serves to trap and contain gas, heat or other hazards when closed.

[0013] Unlike a conventional single-use blowout panel, the blowout panel 190 of the present device 100 is configured to remain fully functional and operational after opening (Fig. 2), so as to permit closing and re-sealing (e g., hermetic re-sealing) (Fig. 1) of the airspace 125 as described further below. This means that the device 100 may help to mitigate against the potential for pressure, heat and gaseous toxins to spread, perhaps in a manner that could lead to the spread of a fire to adjacent packaging already subject to its own fire hazards. However, the re-closing of the panel 190 also means that the hazard within the package 100 itself may be mitigated all the way down to the battery 150 and even on a cell 155 by cell 155 level.

[0014] Once a sufficient pressure release is attained from the opening of the panel 190 (Fig. 2), the closing of the panel 190 covers the opening 175 (Fig. 1). As a result, the intake of oxygen to feed any fire that may be present in the airspace 125 is also eliminated. Thus, the panel 190 ultimately serves as both a pressure and heat release mechanism when opened (Fig. 2) and minimizes fuel for any fire within the device 100 when closed (Fig. 1 ). This occurs by addressing the immediate need to manage any sudden spike in pressure or heat buildup by opening (Fig. 1) and then, once pressure has dropped due to the opening of the panel 190, the re-closing (Fig. 2) now addresses any fire within by preventing the influx of oxygen through the illustrated opening 175. Of course, this also stops the leakage of any added toxic gas and heat from the airspace 125 into the surrounding environment 126. Asdetailed further below, in one embodiment, the mechanism for achieving this dual purpose from the panel 190 may itself be pressure based in a fully passive manner.

[0015] For lithium-ion battery packaging, a pressure of below about 5 PSI within such an airspace 125 may be expected. However, pressure between about 5 and about 10 PSI may be a sign of heat buildup or other issues emerging and once about 20 PSI is reached, the likelihood is that a fire is taking place within the body 110 of the device 100. Therefore, in one embodiment, a predetermined safety range of pressure may be set at anywhere below about 5 PSI. However, when pressure reaches a potentially hazardous level of 5 PSI or more, this is often indicative of a sudden spark or heat release from the battery 150.

[0016] For the embodiment illustrated, a predetermined trigger level of 5 or more PSI may effectuate opening of the panel 190. That is, the panel 190 is coupled to the body 110 of the device packaging 100 by way of a biasing mechanism 160 in the form of a hinge. The hinge 160 may be a pully or spring actuated device with a predetermined level of tension to keep the panel 190 in a normally closed position (Fig. 1). This level of tension may be set in a manner to keep the panel closed (Fig. 1 ) until the predetermined target level of pressure, in this example, 5 PSI, is reached within the airspace 125 of the device 100 (Fig. 2). Factors such as the weight of the panel 190, the added degree of retention from a retention mechanism such as a magnet 192 keeping the panel 190 closed and others may be factored into the naturally closed position of the panel 190 (Fig. 1). Of course, these factors may become more intricate depending on the location of the panel 190 which may vary from one embodiment to the next. In the illustrated embodiment, the opening 175 and the panel 190 are positioned at a side of the device 100. In other embodiments, the opening 175 and the panel 190 can be positioned in a corner of the device 100 or on the top of the device 100, for example.

[0017] As suggested, an added retention mechanism 192 such as a magnet may be utilized and factored in to ensuring the appropriate amount of resistance to opening of the panel 190 during device operation. However, as with a spring-loaded hinge as the biasing mechanism 160 to encourage natural closing of the panel 190, the use of an added retention mechanism 192 is not necessarily required for effective operation of the device 100 as described herein. Nevertheless, use of such features may be encouraged for more practical reasons such as added precision in setting the desired target pressure responsiveness for the panel 190 and for sake offactors outside of pressure within the airspace 125. For example, keeping the panel 190 closed during transport and handling of the device 100 may make for a more user-friendly undertaking. Thus, where the biasing mechanism 160 is a conventional hinge and the added retention mechanism 192 is a magnet is located roughly opposite the hinge 160, a noticeable degree of security to help avoid unintentional opening of the panel 190 during shipping may be of a practical benefit. In the illustrated embodiment, the device 100 includes a corresponding magnet 112 proximate the opening 175.

[0018] Referring now to Fig. 2, in the illustrated embodiment, the panel 190 further includes a sealing element 194 at the edge of the panel 190 for an interface mating with a matching seal 114 at the body 110 of the device 100. In some embodiments, the sealing element 194 and the matching seal 114 may extend around the entire perimeter of the opening 175 to the airspace 125 within the device 100, or they can be arranged in various other configurations that allow the panel 190 includes the capacity to reliably occlude the opening 175 to the airspace 125.

[0019] For the closed position of the panel 190 as shown in Fig. 1 , pressure within the airspace 125 has not yet exceeded a predetermined target of, for example, 5 PSI. Of course, once pressure rises above the predetermined target, the panel 190 may open (see Fig. 2). As referenced above, the naturally closed position of the panel 190 may be maintained by the magnet 192 on the panel 190 and the magnet 112 proximate the opening 175 to encourage the closed position. Of course, alternative implements such as a latch, keyed fitting or other interfacing feature may be utilized that is also reversibly overcome upon exposure to the sufficient predetermined target pressure within the airspace 125 of the device 100. So long as the interfacing allows for opening of the panel 190 along with re-sealing thereof, depending on pressure conditions, benefit may be realized.

[0020] Referring now to Fig. 3, a chart depicting pressure within an embodiment of a fire containment device is illustrated. Specifically, Fig. 3 represents use of an embodiment of a fire containment device as described herein over a period of time for which different events or circumstances may present themselves to the device 100 (Fig. 1). Notice that the potential for issues to arise exists, particularly in the case of lithium-ion battery packaging. This is shown where pressures move from a standard operating pressure below about 5 PSI at 300 and may display certain pressure rises or spikes 325. These rises may be the result of any number ofnaturally occurring events within a battery 150 (Fig. 1) that being stored in the device (i.e., not being used for powering any electronic device). For example, a single battery cell 155 or other isolated portion of the power source 150 may begin to leak, explode, overheat or otherwise display a pressure inducing off-gas event. This pressure increase may not necessarily lead to a significant concern. However, as described above, the potential for exceeding a predetermined target pressure 350, should conditions worsen, may persist.

[0021] With the above in mind, notice that the responsiveness of the opening of the panel 190 (Fig. 2) as detailed herein allows for release of this pressure at 350 as opposed to compromising the entire device 100. For a more conventional device, perhaps with a package of compromised integrity, the pressure may continue to rise with the potential for thermal runaway and / or other issues spreading from cell 155 to cell 155 of the battery 150 (see Fig. 1 ). However, to avoid this type of runaway or complete fire that might be found at about 20 PSI, the present embodiments allow for a real-time pressure release (Fig. 2) and resealing (Fig. 1) of the airspace 125. As a result, thermal runaway spreading to other packaging and / or a fire that is now spreading throughout a facility, large scale equipment or a transport vehicle and so forth may be avoided.

[0022] Instead of such potentially disastrous failure as described above, embodiments herein provide an architecture and modes of operation that manage both the initial pressure release of a potentially hazardous condition (350) by opening (Fig. 2) of the panel190 while also re-closing once this pressure release is achieved (Fig. 2). By reclosing without first having compromised package integrity, the airspace 125 is once again presented with a sealed condition that starves any potential fire of oxygen from the surrounding ambient environment 126 which may halt any continue spreading. This is reflected in Fig. 3 where the pressure rise over 5 PSI has resulted in the described opening of the blowout panel 190 (Fig. 1 ). This is followed by a closing of the panel 190 (Fig. 1). Thus, while maintaining integrity of the device 100 by opening, the re-closing of the panel 190 has now isolated the airspace 125 and prevented influx of oxygen through the opening 175 for feeding a fire (Fig. 1).

[0023] In more specific terms of methodology and reference to Fig. 1 , with a battery 150 prone to overheating or reactions that might pose a risk of sudden pressure increases, the architectural setup of the blowout panel 190 is provided to modulatethe pressure within the housing. With such a layout available, the panel 190 may be utilized to remain closed so long as pressure in the housing 110 is at a level below that of a predetermined target, set at an acceptable safety level. However, should this target pressure be exceeded by actual conditions within the housing 110, the panel may be opened (Fig. 2) to allow for a release of the pressure. Of course, the panel 190 may also be reclosed once pressure drops below the predetermined target.

[0024] Where the failure of one battery cell 155 occurs in a manner resulting in a pressure spike 325, the opening of the panel 190 (Fig. 1) may at first prevent a conflagration. The subsequent reclosure of the panel 190 (Fig. 1) means a resealing of the airspace 125 then occurs to help avoid the intake of additional oxygen that might be available to fuel any adjacent battery cell 155 reaction or fire. Thus, the opening (Fig. 2) and re-closing (Fig. 1) of the panel 190 is repeatable in a manner that may even help issues in any one battery cell 155 avoid cascading issues to adjacent cells 155. The opening (Fig. 2) and reclosing (Fig. 1) may be automatic and self-repeating even in circumstances where a sudden explosion has occurred.

[0025] Embodiments described hereinabove include a fire containment device particularly beneficial for minimizing toxic gas release and even preventing fire and thermal runaway for batteries prone to exhibit pressure increases, sudden fire and other failure modes that may be particularly hazardous. This not only improves safety for users and the surrounding environment but also increases the likelihood of preventing complete failure of the battery itself in the first place. That is, for embodiments herein, the device and blowout panel are configured to remain structurally functional and operational in many circumstances even after facing suddenly explosive or fire starting conditions.

[0026] The preceding description has been presented with reference to presently preferred embodiments. Persons skilled in the art and technology to which these embodiments pertain will appreciate that alterations and changes in the described structures and methods of operation may be practiced without meaningfully departing from the principle, and scope of these embodiments. Furthermore, the foregoing description should not be read as pertaining only to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope.

Claims

CLAIMSWhat is claimed is:1 . A fire containment device, comprising: a housing with an interior housing airspace and a housing opening, wherein the housing is configured to store a battery such that the battery is exposed to the housing airspace; and a blowout panel disposed relative to the housing opening and transitionable between a closed state, in which the blowout panel obstructs the housing opening to prevent fluid communication between the housing airspace and an ambient environment, and an open state, in which the blowout panel permits fluid communication between the housing airspace and the ambient environment via the housing opening; wherein the blowout panel is biased toward the closed state with a bias force; wherein the blowout panel transitions from the closed state to the open state when a pressure in the housing airspace is sufficient to overcome the bias force; wherein the blowout panel remains in the open state while the pressure in the housing remains sufficient to overcome the bias force; and wherein the blowout panel transitions from the open state to the closed state when the pressure in the housing airspace is no longer sufficient to overcome the bias force.

2. The fire containment device of claim 1 , wherein the battery is a lithium-ion battery.

3. The fire containment device of claim 1 , wherein the blowout panel transitions from the closed state to the open state when the pressure in the housing airspace is greater than 5 PSI.

4. The fire containment device of claim 1 , further comprising a biaser configured to supply the biasing force to the blowout panel.

5. A method of modulating pressure in a fire containment device, the method comprising: positioning a battery in a housing having a pressure below a predetermined target; maintaining a panel of the housing closed with the pressure below the predetermined target; opening the panel of the housing upon the pressure reaching at least the predetermined target; and reclosing the panel upon the pressure returning to a level below the predetermined target.

6. The method of claim 5, wherein the opening facilitates at least one of toxic gas removal and heat removal from the airspace.

7. The method of claim 5, wherein the reclosing facilitates at least one of reducing oxygen supply to any fire in the airspace and reducing toxic gas release from the airspace.

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