Sandwich Battery Module Frame for Thermal Runaway Resistance
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Solution Overview
Problem
Battery module frames face structural collapse and secondary damage from external fires or explosions due to overheated battery cells, which can lead to thermal runaway and oxygen supply, causing large-scale fires or explosions.
Innovation Solution
A battery module frame composed of a sandwich structure with a first layer of aluminum or aluminum alloy, a second layer of heat-resistant reinforced plastic, and a third layer of aluminum or aluminum alloy, featuring ventilation portions and fastening options like welding or bolting, to prevent structural collapse and optimize flame suppression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional single-material frame is used, then the frame structure is simple and easy to manufacture, but the frame collapses structurally when exposed to high temperatures from overheated battery cells
Solution Approach 1:
The frame employs a composite structure consisting of an aluminum alloy outer layer and an inner layer made of either heat-resistant plastic or fire-resistant metal. This multi-material construction provides both high-temperature resistance and structural strength, preventing frame collapse during thermal runaway events while maintaining manufacturability through standardized assembly processes
2Strength
If the frame is made entirely of heat-resistant material, then structural collapse is prevented, but the frame weight increases significantly
Solution Approach 1:
The frame applies heat-resistant materials selectively in the inner layer that directly contacts the battery cells, while the outer aluminum alloy layer provides structural support with lower weight. This localized application of heat-resistant properties ensures protection where needed most while minimizing overall weight increase compared to a full heat-resistant construction
3Object-affected harmful factors
If ventilation portions are added to the frame, then flame suppression is improved by limiting oxygen supply, but the frame structure becomes more complex
Solution Approach 1:
The frame incorporates ventilation portions as discrete segmented openings in the outer aluminum alloy layer. These segmented openings allow controlled oxygen limitation to suppress flame propagation while maintaining structural integrity. The segmentation approach enables fire suppression functionality to be added as a separate feature rather than requiring a complete redesign of the frame structure
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 structure with heat-resistant reinforced plastic interposed between aluminum layers provides a lightweight, fire-resistant frame that suppresses structural collapse and reduces the risk of fire propagation, ensuring safety by preventing oxygen supply to internal flames.
Implementation Method 1
a second layer stacked on the first layer and made of a reinforced plastic material with a higher melting point than the first layer
Data Source
AI summary
A polyhedral battery module frame in which a plurality of battery cells are accommodated includes a first layer made of an aluminum or aluminum alloy material, a second layer stacked on the first layer and made of a reinforced plastic material with a higher melting point than the first layer, and a third layer stacked on the second layer and made of an aluminum or aluminum alloy material.