Battery Pack Gasket Shielding Against Thermal Runaway Flames
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Solution Overview
Problem
The pack gasket in battery packs is vulnerable to damage from high-temperature gases or flames generated during thermal runaway, leading to potential leaks and secondary damage.
Innovation Solution
A battery pack design that includes a blocking structure, such as first and second protruding parts on the side wall frame, to protect the pack gasket from internal flames, along with a flame blocking bracket at the corner to prevent direct exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pack gasket is made of flexible rubber for sealing, then the sealing performance is improved, but the gasket easily melts when exposed to flames
Solution Approach 1:
A blocking structure is introduced as an intermediary element between the battery modules and the pack gasket. This blocking structure absorbs or blocks the high-temperature gases and flames generated during thermal runaway, preventing direct contact with the pack gasket and maintaining its sealing integrity.
Solution Approach 2:
The battery pack interior is segmented into protected and unprotected zones by the blocking structure. The pack gasket is positioned in a protected zone shielded from thermal events, while the blocking structure occupies the zone between the battery modules and the gasket, creating spatial separation that protects the sealing component.
2Strength
If the upper lid and side wall frame are formed of metal to withstand high temperature, then the structural strength at high temperature is improved, but the pack gasket still melts when exposed to internal flames
Solution Approach 1:
The blocking structure serves as a thermal barrier intermediary between the metal housing (which withstands high temperature) and the pack gasket (which is sensitive to heat). Even though the metal housing can resist high temperatures, the blocking structure provides an additional protective layer that prevents direct flame and hot gas contact with the temperature-sensitive gasket.
3Device complexity
If no blocking structure is installed, then the device complexity is reduced, but the pack gasket is vulnerable to thermal runaway damage
Solution Approach 1:
The blocking structure is designed as a simple geometric feature (protrusion from the side wall frame) that segments the interior space without requiring complex additional components. This minimal structural modification provides effective thermal protection while maintaining manufacturing simplicity.
Data Source
AI summary
A battery pack includes a lower pack housing including a bottom plate and a side wall frame surrounding edges of the bottom plate; an upper lid coupled to an upper surface of the side wall frame while covering the lower pack housing; and a pack gasket installed between the upper surface of the side wall frame and the upper lid, in which a first protruding part blocking the inside of the battery pack and the pack gasket is provided along the upper surface of the side wall frame.