Battery Pack Case Sealing for Fire Gas and Flame Containment
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Solution Overview
Problem
Large-capacity battery packs, particularly in electric vehicles, face safety concerns due to the risk of fires or explosions, which can lead to the spread of flames and high-temperature gases, causing damage and injury.
Innovation Solution
A battery pack design featuring a pack housing with a sealing member that melts at high temperatures to fill gaps between cases, preventing the discharge of flames or gases, and includes a mounting member and guide member to direct the molten sealing material effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a large-capacity battery module with multiple battery cells is used to increase energy storage capacity, then the energy density and power output are improved, but the risk of fire or explosion increases and flame can spread to other battery packs
Solution Approach 1:
The battery pack housing is divided into multiple separate cases (first case, second case, third case) that are coupled together with gaps between them. This segmentation allows the housing to contain fire within a limited section while preventing flame spread to other battery packs through the gap-sealing mechanism.
Solution Approach 2:
A sealing member is introduced as an intermediary component between the battery module and the housing cases. This sealing member includes a flame-retardant layer and a gap-sealing layer that actively responds to thermal conditions by melting and flowing into gaps to prevent flame and gas discharge.
2Strength
If the pack housing is designed with coupled cases to accommodate the battery module, then the structural integrity and accommodation capacity are improved, but gaps between cases can discharge flames or high-temperature gases during fire or explosion
Solution Approach 1:
The sealing member changes its physical parameters in response to temperature changes. At normal temperatures, it maintains a solid structure. When exposed to high temperatures (fire conditions), it melts and flows into the gaps between housing cases, changing from a static seal to an active flame-blocking barrier.
Solution Approach 2:
The sealing member is pre-installed in positions that allow it to flow into gaps when melted. The mounting members and guide grooves are designed in advance to direct the molten sealing material into the gaps between housing cases, ensuring rapid sealing action when fire occurs.
3Reliability
If a sealing member is added to prevent flame discharge through gaps, then the safety against fire spread is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The sealing member uses a flexible, heat-responsive material that can deform and flow under thermal conditions. This flexible sealing approach is simpler than rigid mechanical sealing systems, as it automatically adapts to gap variations and housing deformations during fire events.
Solution Approach 2:
The sealing member is self-activating through its heat-responsive properties. When exposed to fire, it automatically melts and flows into gaps without requiring external control systems, actuators, or complex mechanisms. The mounting members with guide grooves simply direct the self-flowing material.
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
The solution effectively prevents the external discharge of high-temperature gases or flames during a fire or explosion, enhancing safety by sealing the gaps between the cases, thereby reducing the risk of damage and injury.
Implementation Method 1
a sealing member configured to be melted at a predetermined temperature or higher to flow into a gap between one end of the first case and the other end of the second case
Data Source
AI summary
A battery pack includes a battery module including a plurality of battery cells; a pack housing configured to accommodate the battery module therein, and including a first case configured to cover one side of the battery module and having an open other side, and a second case configured such that it covers the other side of the battery module, one side thereof is open, and one side end thereof is coupled to the other side end of the first case; and a sealing member configured to be melted at a predetermined temperature or higher to flow into a gap between one end of the first case and the other end of the second case.