Battery Pack Enclosure Intumescent Shielding for Gasket Seal Protection
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Solution Overview
Problem
Traction battery packs face challenges in sealing interfaces to prevent gas venting and thermal energy propagation during thermal events, which can lead to pressure and temperature increases, potentially rupturing battery cells and compromising the integrity of the gasket seal.
Innovation Solution
The use of an intumescent material sandwiched between the flanges of the enclosure pieces, which expands to shield the gasket seal from thermal energy and maintain the seal integrity by directing vented gas and thermal energy away from the gasket seal, combined with strategically spaced and fastened flanges to enhance thermal dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gasket seal is used to seal the interface between enclosure pieces, then sealing effectiveness is improved, but the gasket seal is vulnerable to thermal energy propagation during thermal events
Solution Approach 1:
An intumescent material is introduced as an intermediary layer between the gasket seal and the battery cells. This intumescent material acts as a protective mediator that absorbs and blocks thermal energy propagation, preventing direct thermal exposure to the gasket seal while maintaining the sealing function.
Solution Approach 2:
The intumescent material is positioned beforehand between the flanges and gasket seal to provide thermal protection. During thermal events, this pre-positioned material expands to create an insulating barrier, cushioning the gasket seal from thermal damage before the thermal energy can reach it.
2Temperature
If flanges are spaced apart outside the gasket seal area, then thermal dissipation is enhanced, but structural connection strength is reduced
Solution Approach 1:
The flange connection structure is segmented into two functional zones: an inner region where flanges are closely spaced to provide structural strength and secure the gasket seal, and an outer region where flanges are spaced apart to enable thermal dissipation. This segmentation allows both conflicting requirements to be satisfied in different spatial locations.
Solution Approach 2:
Different spatial regions of the flange interface are assigned different qualities: the inner region has close spacing for mechanical strength, while the outer region has wide spacing for thermal management. This local differentiation of structural properties resolves the contradiction between strength and thermal dissipation.
3Object-affected harmful factors
If an intumescent material is added between flanges, then thermal shielding of the gasket seal is improved, but device complexity increases
Solution Approach 1:
The intumescent material serves multiple functions simultaneously: it provides thermal insulation to protect the gasket seal, acts as a space filler between the flanges, and contributes to the overall structural integrity of the assembly. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
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
Effectively prevents gas venting through sealed interfaces and manages thermal energy, ensuring the gasket seal's integrity and safe release of vented gases to the ambient environment, thereby protecting the battery cells from damage.
Implementation Method 1
an intumescent sandwiched between the first and second flange at a position that is between the gasket seal and the interior area
Implementation Method 2
the intumescent is configured to expand to seal an interface between the first and second flanges at the position
Data Source
AI summary
An assembly includes a first piece and a second piece of an enclosure having an interior area. The first piece includes a first flange that projects outward from the interior area. The second piece includes a second flange that projects outward from the interior area. The assembly further includes a gasket seal and an intumescent. The gasket seal is sandwiched between the first and second flanges. The intumescent is sandwiched between the first and second flange at a position that is between the gasket seal and the interior area.