Mesh-Layer Battery Module Frame for Thermal Runaway Venting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Secondary battery modules face the risk of thermal runaway and subsequent fire or explosion, with flames potentially spreading outside the module frame, causing secondary damage.
Innovation Solution
A battery module frame composed of a first layer of aluminum, a second layer with a mesh metallic structure, and a third layer of aluminum, where the mesh layer is made of a material with a higher melting point than the aluminum layers, and ventilation portions are strategically placed to prevent flame exposure and extinguish fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid metal frame structure is used to contain battery cells, then structural strength and flame containment are improved, but weight increases and ventilation for heat dissipation becomes difficult
Solution Approach 1:
The patent applies a mesh structure made of heat-resistant material with controlled porosity (opening ratio of 30-70%) that allows ventilation for heat dissipation while maintaining structural integrity and flame containment capabilities. The mesh structure provides both mechanical strength and thermal management functionality simultaneously.
Solution Approach 2:
The patent uses composite material construction combining a mesh structure of heat-resistant material (such as ceramic-coated metal or high-temperature alloy) with supporting framework elements, creating a lightweight yet strong frame that resists thermal runaway while reducing overall weight compared to solid metal frames.
2Temperature
If ventilation portions are added to the frame to allow heat dissipation, then thermal management is improved, but flame exposure risk to the outside increases
Solution Approach 1:
The mesh structure with controlled porosity allows selective passage of heat and gases while the heat-resistant material and mesh geometry filter out flames. The opening ratio is optimized to permit thermal energy dissipation while preventing combustible flame propagation to the external environment.
Solution Approach 2:
The frame design incorporates localized ventilation portions at specific locations rather than uniform openings, with the mesh structure having varying density in different regions. This allows optimized heat dissipation pathways while maintaining flame containment in critical areas.
3Temperature
If a mesh structure with high porosity is used for ventilation, then heat dissipation is improved, but structural strength and flame containment capability deteriorate
Solution Approach 1:
The patent specifies an optimal porosity range (opening ratio of 30-70%) for the mesh structure that balances ventilation efficiency with structural integrity. The mesh geometry, wire diameter, and spacing are designed to provide sufficient mechanical strength while allowing adequate heat dissipation.
Solution Approach 2:
The use of heat-resistant composite or coated materials enhances the mechanical properties of the mesh structure at high temperatures, allowing higher porosity designs that maintain both strength and thermal management performance under operating conditions.
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 frame effectively suppresses flame spread by using the mesh structure to extinguish internal flames and prevent them from being discharged externally, while maintaining a lightweight structure and facilitating assembly through welding and bolting.
Implementation Method 1
the mesh structure to extinguish internal flames and prevent them from being discharged externally
Data Source
AI summary
A battery module frame accommodates a plurality of battery cells. The battery module frame includes a first layer made of aluminum or aluminum alloy material; a second layer made of metallic material with a mesh structure, and stacked over the first layer; and a third layer made of aluminum or aluminum alloy material, and stacked over the second layer.