Battery Housing Threaded Bushing for Controlled Thermal Venting
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Solution Overview
Problem
Screwed connections in battery housings can detach during thermal events, leading to uncontrolled gas release and potential leakage, as the existing threaded connections fail under extreme pressure, compromising safety.
Innovation Solution
The battery housing employs threaded bushings made of a combination of metallic and thermoplastic materials, where the thermoplastic component melts or breaks down at a predetermined temperature, causing the screw to detach without damaging the through holes, maintaining the seal and allowing the housing to vent gases safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If screwed connections are used to connect housing parts, then the housing can be assembled and disassembled for servicing, but the screwed connections can become detached during thermal events causing uncontrolled gas release
Solution Approach 1:
The threaded connection is segmented into two functional parts: a metal thread portion for secure attachment and a thermoplastic portion that melts at a predetermined temperature. This segmentation allows the connection to maintain stability during normal operation while providing a controlled failure mode during thermal events, resolving the contradiction between serviceability and thermal safety.
Solution Approach 2:
The threaded bushing utilizes parameter changes in the thermoplastic material's thermal properties. The material is selected to melt at a specific temperature threshold, transforming the connection from a rigid mechanical joint to a controlled-release mechanism. This parameter change enables the connection to remain stable during servicing while automatically failing safely during thermal runaway events.
2Ease of operation
If extreme excess pressure is applied to screwed connections, then the housing can be opened for access, but the screwed connections can be destroyed causing leakages
Solution Approach 1:
The potential harmful effect of extreme pressure destroying the connection is converted into a beneficial controlled failure mode. The thermoplastic material's melting under pressure transforms an uncontrolled destruction scenario into a predictable, safe release mechanism that prevents gas leakage through damaged threads while still allowing housing access when needed.
Solution Approach 2:
The thermoplastic material acts as a beforehand cushioning element that absorbs and manages extreme pressure conditions. Before the metal thread portion can be damaged, the thermoplastic material yields and melts, cushioning the system against the harmful effects of excessive force and preventing catastrophic connection failure and gas leakage.
3Ease of manufacture
If through holes are formed in housing parts for screwed connections, then the housing can be assembled, but the through holes can be torn open during thermal events allowing uncontrolled gas escape
Solution Approach 1:
The threaded bushing with its thermoplastic material performs a preliminary protective action by being installed in the through hole before any thermal event occurs. This preliminary configuration ensures that during thermal runaway, the thermoplastic material will melt and allow the bushing to detach controllably, preventing the through hole from being torn open and enabling safe, controlled venting instead of uncontrolled gas escape.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design ensures the battery housing remains sealed during thermal events, preventing gas escape and allowing safety elements to react effectively, thereby enhancing safety by maintaining the integrity of the seal and controlling pressure release.
Implementation Method 1
the threaded bushings are at least partially made of a material that melts or breaks down during a thermal event within its proximity
Implementation Method 2
the threaded bushings are at least partially made of a material that melts or breaks down during a thermal event within its proximity
Data Source
AI summary
A battery housing includes a first housing part and a second housing part that are connected to one another via a screw. The first housing part has a threaded bushing with a thread that is connected to the first housing part. The second housing part has a through hole. The screw is disposed through the through hole and in the threaded bushing. The threaded bushing is at least partially made of a material that melts, softens, or breaks down during a thermal event.