Fire-Resistant Battery Module Cover for Thermal Runaway Containment
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Solution Overview
Problem
Electrically powered vehicles face safety risks due to thermal runaway in battery modules, which can lead to rapid fire spread, posing a threat to operators and requiring effective management to delay or slow down the fire spread.
Innovation Solution
The implementation of a battery thermal runaway management system using fire-resistant covers made from materials like mica, integrated as a single unitary body over battery modules, combined with fire-resistant foam layers to deflect hot gases and inhibit fire spread, allowing for increased time to safely exit the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery modules are used to supply power for electrically powered vehicles, then sufficient power for propelling the vehicle is achieved, but large amounts of heat are generated during use
Solution Approach 1:
A fire-resistant barrier comprising a cover and fire-resistant foam is introduced as an intermediary between battery modules. The cover extends over the top and sides of the battery module, and fire-resistant foam is injected between the cover and battery module to create a thermal barrier that mediates heat transfer, allowing high power operation while managing heat generation
Solution Approach 2:
The fire-resistant barrier uses composite materials including fire-resistant foam and mica-based materials. The foam provides thermal insulation while the mica material (which can withstand temperatures of at least 750°C for 10 minutes) provides fire resistance, creating a composite structure that addresses both heat generation and fire safety
2Reliability
If thermal runaway occurs in battery modules, then rapid fire spread occurs, but operator safety is compromised
Solution Approach 1:
The fire-resistant cover is configured to extend over the top and each side of the battery module, creating segmented protection zones. Divider walls may extend between mutually facing sides of adjacent battery modules, segmenting the fire containment zones and preventing rapid fire spread between modules, thereby controlling fire spread while protecting operators
Solution Approach 2:
The fire-resistant barrier is installed beforehand as a protective cushion between battery modules. The fire-resistant foam and cover material are positioned in advance to cushion against thermal runaway effects, providing a buffer that protects operators and slows fire spread before thermal runaway occurs
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 system effectively delays the spread of fire from one battery module to another, providing operators with sufficient time to exit safely by utilizing fire-resistant materials that withstand high temperatures, thereby enhancing the safety of electrically powered vehicles.
Implementation Method 1
the cover being integrally formed as a single unitary body from a fire-resistant material... fire-resistant foam layers to deflect hot gases... materials like mica... withstand high temperatures
Data Source
AI summary
A battery runaway management system includes at least one battery module and a cover. The cover extends over a top and each side of the at least one battery module. The cover is integrally formed as a single unitary body from a fire-resistant or fire-retardant material.