Battery Cell Mesh Containment and Pressure Relief Venting

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Solution Overview

Problem

High-powered Lithium-Ion batteries in portable devices and motor vehicles are prone to unintended malfunctions such as explosions and venting due to increased electrical demand, which existing technologies fail to adequately address.

Innovation Solution

A battery design featuring a mesh surrounding the cells to contain explosive parts and a pressure relief feature that allows gas to escape when pressure exceeds a threshold, combined with thermal barriers and a mesh material that is fire-resistant and electrically insulating, with options for a one-way valve or structurally weakened casing portions for pressure relief.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If high-powered Lithium-Ion batteries are used to meet increased electrical demand, then power and energy storage capacity are improved, but the risk of unintended malfunctions such as explosions and venting increases

Engineering Contradiction:

Improvebattery powerVSAvoidbattery safety

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The battery system is segmented into individual cells, each surrounded by its own mesh containment structure. This segmentation ensures that if one cell fails, the failure is contained within that cell's mesh boundary and cannot propagate to other cells, thus maintaining system reliability while allowing high power operation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Mesh containment structures are installed around each battery cell before operation to provide pre-established protection. These meshes act as cushioning barriers that will contain cell parts if an explosion occurs, preventing the propagation of failures and maintaining overall battery safety despite high power demands

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Strength

If the battery casing is made strong to contain cells, then structural strength is improved, but the risk of overpressurization from gas venting increases

Engineering Contradiction:

Improvecasing strengthVSAvoidoverpressurization

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The casing is designed with non-uniform local quality: most of the casing maintains high structural strength to contain cells, while specific localized regions incorporate pressure relief features. This allows the casing to be strong overall while having designated weak points that prevent overpressurization by allowing controlled gas venting

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Pressure relief valves or vent holes act as intermediary elements between the strong casing and the internal gas pressure. These intermediaries provide a controlled path for gas escape, mediating between the conflicting requirements of casing strength and overpressurization prevention

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a mesh is added to contain cell parts, then safety against explosions is improved, but the device complexity increases

Engineering Contradiction:

Improveexplosion containmentVSAvoidbattery structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Thin mesh screens are used instead of bulky containment structures. These flexible, thin-film meshes provide effective explosion containment while adding minimal structural complexity and volume to the battery assembly

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The mesh containment structures can be made from composite materials that combine fire resistance, electrical insulation, and mechanical strength in a single component, reducing the need for multiple separate protective elements and thereby simplifying the overall device structure

Inventive Principle:

Principle #40Composite materials

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 contains exploding battery cell parts and prevents overpressurization, ensuring safety by allowing gas venting and utilizing thermal barriers to manage heat, thereby reducing the risk of malfunctions and ensuring safe operation in devices like laptops and motor vehicles.

Implementation Method 1

The mesh is porous to gas emitted by the cells such that the gas can pass through the mesh to the casing

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 2

At least one pressure relief feature is arranged to permit gas to pass through the casing when pressure in the casing exceeds a threshold

Methodology Applied

Scientific EffectPressure relief: Depressurisation

Implementation Method 3

thermal barriers may be disposed between adjacent cells. A thermal barrier may include a ceramic plate

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS9281506B2Battery cell containment and venting

Publication Date: 2016.03.08 LENOVO SWITZERLAND INTERNATIONAL GMBH

AI summary

A battery has a casing holding plural cells and a mesh wrapped around the cells to contain pieces of an exploding cell within the casing. To prevent overpressurization of the casing from the gas emitted by an exploding cell, a pressure relief feature is provided that allows gas to pass through battery casing.