Plastic Battery Support Frame for Thermal Runaway Containment
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Solution Overview
Problem
Existing battery electric vehicles face significant safety hazards due to thermal runaway in battery cell modules, which can trigger uncontrolled chain reactions and fires, and existing safety systems are inadequate in preventing the spread of fluids and solids.
Innovation Solution
A support frame with fluid-tight compartments and a battery box design that uses a plastic material with fiber-reinforced elements and metallic reinforcement to contain and drain escaping fluids and solids during thermal runaway, featuring integrated venting and temperature control mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery modules are housed in a conventional battery box without fluid-tight compartmentation, then the structure is simpler and manufacturing is easier, but thermal runaway can spread uncontrolled to neighboring modules via heat conduction and fluid leakage
Solution Approach 1:
The battery box is divided into multiple fluid-tight receiving compartments by transverse and longitudinal beam struts that material-bondedly connect to the frame body. Each compartment houses individual battery modules and prevents the uncontrolled spread of fluids and solids during thermal runaway, while maintaining a relatively simple overall structure.
2Strength
If a rigid support frame structure is created to prevent deformation during crashes, then occupancy protection is improved, but the frame becomes heavier and more complex
Solution Approach 1:
The frame body and beam struts are made from fiber-reinforced plastic material, combining the strength and stiffness of fibers (such as glass or carbon fibers) with the lightweight and corrosion-resistant properties of plastic. This composite material achieves high structural rigidity for crash protection while maintaining lower weight compared to traditional metal frames.
3Reliability
If fluids and solids are allowed to spread freely during thermal runaway, then the drainage system would be simpler, but the risk of chain reactions to neighboring modules increases
Solution Approach 1:
The drainage system is segmented into compartment-specific drainage paths. Each receiving compartment has its own drainage outlet that discharges fluids and solids locally within or near the compartment of origin, preventing cross-contamination between compartments. This segmented approach contains hazards while maintaining a relatively simple drainage infrastructure.
4Strength
If the frame body and beam struts are made from fiber-reinforced plastic material, then the strength-to-weight ratio is improved and corrosion resistance increases, but manufacturing complexity and material cost increase
Solution Approach 1:
The frame body and beam struts are manufactured as an integral one-piece structure using fiber-reinforced plastic material. This merging of components into a single molded part eliminates the need for separate manufacturing and assembly of multiple pieces, simplifying production despite the advanced material used. The one-piece design also eliminates potential weak points at joints.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~3A
AI summary
Support frame for receiving battery modules for a battery-electric vehicle, comprising a circumferential frame body with a frame top and a frame bottom for delimiting a frame interior, and at least one cross member strut and/or at least one longitudinal member strut, which are arranged within the frame interior and are load-bearing and materially connected to the circumferential frame body to form a plurality of receiving compartments for battery modules within the frame interior, wherein the frame body has two opposing longitudinal side elements and two opposing transverse side elements, and wherein the elements of the frame body and the at least one cross member and/or longitudinal member strut are made of a plastic material.