Battery Module Flame Arrestor With Mesh-Baffle Gas Cooling
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Solution Overview
Problem
Lithium-ion batteries pose a fire and explosion hazard due to thermal runaway, which can occur from physical damage, improper use, or electrical abuse, releasing heat, sparks, molten particles, and gases that can ignite and cause chain reactions.
Innovation Solution
A flame arrestor design comprising a multi-layer mesh screen and an accordion-shaped baffle, positioned adjacent to the battery cell, which prevents sparks and molten particles from escaping and creates a channel for gases to cool before exiting, thereby reducing the risk of ignition and compliance with stringent fire safety regulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flame arrestor is added to prevent sparks and molten particles from escaping, then fire safety is improved, but device complexity increases
Solution Approach 1:
The flame arrestor is divided into multiple functional layers: a mesh screen layer for particle filtration and a baffle layer for spark containment. This segmentation allows each layer to perform its specific function efficiently while maintaining overall system reliability without excessive complexity
Solution Approach 2:
The baffle structure is positioned within the mesh screen assembly, with the baffle extending between the first and second mesh screens. This nested configuration maximizes the protective function within a compact structure, improving fire safety without proportionally increasing device complexity
2Temperature
If a baffle structure is added to create cooling channels for gases, then temperature control is improved, but device complexity increases
Solution Approach 1:
The baffle is designed as a separate component with integrated cooling channels, distinct from the mesh screen but positioned within the same assembly. This segmentation allows the cooling function to be added without completely redesigning the filtration structure
Solution Approach 2:
The baffle structure serves multiple functions: it creates cooling channels for gas temperature reduction, provides structural support between mesh screens, and contributes to the overall flame arrestor framework. This multi-functionality improves temperature control while minimizing the increase in device complexity
3Reliability
If multiple layers of mesh are used to offset holes, then particle containment is improved, but manufacturing complexity increases
Solution Approach 1:
The mesh containment system uses multiple discrete mesh layers with offset hole patterns. Each layer can be manufactured separately using standard mesh fabrication techniques, then assembled with precise positioning to achieve the offset configuration, improving particle containment while managing manufacturing complexity through modular construction
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 flame arrestor effectively mitigates fire hazards by preventing the escape of sparks and molten particles and allowing gases to cool, decreasing the likelihood of chain reactions and ensuring safer battery operation and compliance with fire safety standards.
Implementation Method 1
The mesh screen may contain multiple layers of mesh offset from one another to occlude straight through-holes and prevent sparks or molten particles from passing through
Implementation Method 2
The baffle may be affixed to the inside of the mesh screen and may be configured to be an added layer of protection to capture molten particles ejected from the cells and create a channel structure for the gasses
Data Source
AI summary
The disclosure generally relates to a flame arrestor device configured to reduce the hazards of a thermal runaway, by containing sparks and molten particles and cooling gasses emitted from the cells. The device may be used in any apparatus that requires a lithium-ion cell battery, such as a data centers, smartphone, tablet, earbuds, etc. The device may include a mesh screen and a baffle. The mesh screen may include multiple layers of mesh offset from each other. The baffle may be formed in a chevron pattern and affixed to the inside of the mesh screen.