Battery Module Frame With Metal Mesh for Flame Quenching
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Solution Overview
Problem
Secondary battery modules face challenges in preventing the spread of external fires or explosions when a battery cell overheats, as existing solutions fail to effectively contain the flame and control thermal runaway, leading to structural collapse and secondary damage.
Innovation Solution
A battery module part comprising a synthetic resin body with a metal mesh embedded inside, where the mesh has a higher melting point than the resin, providing a flame quenching effect and limiting high-temperature gas discharge through vulnerable portions with lower heat resistance, thereby preventing external flame exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery module uses a conventional frame structure without flame containment features, then the module structure is simple and easy to manufacture, but the frame collapses when a battery cell overheats and generates flame, allowing flame exposure outside the module
Solution Approach 1:
The patent applies composite materials by combining a resin body with a metal mesh embedded within it. The resin provides structural integrity while the metal mesh provides flame resistance and structural stability at high temperatures. This composite structure prevents frame collapse during thermal runaway while maintaining manufacturing feasibility through insert injection molding.
Solution Approach 2:
The patent implements local quality by creating vulnerable portions in the resin body with lower heat resistance than surrounding areas. These localized weak points are strategically positioned to control where flame and hot gas escape occurs, directing them through the metal mesh which then quenches the flame. This allows the majority of the frame to maintain structural integrity while providing controlled flame containment at specific locations.
2Reliability
If a battery module frame is designed to prevent flame exposure by using high heat resistance materials throughout, then flame containment is improved, but the frame weight increases and manufacturing complexity increases
Solution Approach 1:
The patent uses a composite structure where a lightweight resin body provides the main frame structure, and a metal mesh provides localized fire resistance. This combination achieves flame containment functionality while keeping the overall frame weight much lower than a fully metal construction would require, as the resin constitutes the majority of the frame volume.
Solution Approach 2:
The patent applies fire-resistant metal mesh only in specific locations where flame containment is critical, rather than throughout the entire frame. The vulnerable portions are strategically placed to control flame escape paths. This localized application of heavy material minimizes overall weight increase while achieving the required flame containment reliability.
3Reliability
If a battery module frame uses a fully enclosed structure to prevent flame exposure, then flame containment is improved, but heat accumulation inside the module increases, worsening thermal runaway conditions
Solution Approach 1:
The patent creates vulnerable portions in the resin body that have lower heat resistance than surrounding areas. These localized weak points serve as controlled escape paths for flame and hot gas, allowing heat to be vented from the module interior. The flame is quenched by the metal mesh during escape, but the heat accumulation is relieved, preventing worse thermal runaway conditions.
Solution Approach 2:
The metal mesh acts as an intermediary element that allows heat and gas to pass through while quenching the flame. It mediates between the need to contain flame exposure externally and the need to release heat internally. The mesh structure provides a controlled pathway that removes thermal energy from the system without allowing unquenched flame to escape.
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 composite material design effectively suppresses flame propagation and external fire risks by allowing only high-temperature gas to be discharged, while the mesh structure absorbs heat and prevents flame ejection, enhancing safety by controlling the discharge location of high-temperature gases.
Implementation Method 1
the mesh structure absorbs heat and prevents flame ejection
Implementation Method 2
A portion of an outer surface of the body may include a vulnerable portion with a lower heat resistance than a surrounding portion of the outer surface of the body
Data Source
AI summary
A battery module part includes a body made of synthetic resin and a mesh made of a metal and embedded in the body. The body has a lower melting point than the mesh.