Battery Pack Frame Sealing for Thermal Runaway Containment
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Solution Overview
Problem
Existing battery packs face issues with thermal runaway, where ignition of a battery cell can lead to high temperature and pressure gas, flames, and metal particles, causing damage to adjacent modules and exposing frames externally, compromising airtightness and safety.
Innovation Solution
A battery pack design with a seating recess in the horizontal frame for connection members, a vertical frame cover to secure module space height, a sealing member to seal the recess, and a double shielding structure to enhance airtightness, including module space and battery pack covers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If connection members pass through the horizontal frame through the seating recess, then the height of the horizontal frame is maximized, but the structural complexity increases
Solution Approach 1:
The connection members are nested within the seating recess of the horizontal frame, allowing the frame to maintain its maximum height while accommodating the connection members internally. This nesting approach avoids external protrusions and maintains a compact structure.
Solution Approach 2:
The seating recess creates a vertical dimension within the horizontal frame, allowing connection members to pass through the frame in a controlled manner. This dimensional approach enables the frame to maintain its external height while providing internal pathways for electrical connections.
2Reliability
If a sealing member is provided in the seating recess to seal the recess, then airtightness is improved, but the manufacturing complexity increases
Solution Approach 1:
A sealing member, likely made of flexible material such as rubber or elastomer, is installed in the seating recess to create an airtight seal. This flexible sealing approach effectively prevents gas and flame propagation while maintaining a relatively simple manufacturing process compared to rigid sealing structures.
Solution Approach 2:
The sealing member acts as an intermediary element between the seating recess and the external environment, providing the airtight barrier needed to prevent thermal runaway propagation. This intermediary component simplifies the overall sealing design by concentrating the sealing function in a single, replaceable part.
3Reliability
If a double shielding structure including module space cover and battery pack cover is provided, then airtightness is maximized, but the device complexity increases
Solution Approach 1:
The shielding structure is segmented into two distinct components: the module space cover that shields individual module spaces, and the battery pack cover that shields the entire battery pack housing. This segmentation allows for modular manufacturing, assembly, and maintenance while achieving comprehensive airtight protection through the combined structure.
Solution Approach 2:
The module space covers are nested within the battery pack cover, creating a hierarchical shielding structure. The module space covers provide localized sealing for individual modules, while the battery pack cover provides overall protection. This nested arrangement achieves maximum airtightness through multiple layers without requiring a completely redundant structure.
4Strength
If vertical frame cover is provided in vertical frame to secure height, then structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The vertical frame structure is segmented with a separate vertical frame cover that can be manufactured independently and then assembled to the main frame. This segmentation allows each component to be optimized for its specific function and manufactured using appropriate processes, reducing overall manufacturing complexity while maintaining structural integrity.
Solution Approach 2:
The vertical frame cover serves multiple functions: it secures the height of the vertical frame, provides structural support, and contributes to the overall airtight sealing when combined with the sealing member. This multi-functionality reduces the need for additional separate components, simplifying the overall manufacturing process.
Data Source
AI summary
Disclosed is a battery pack in which a seating recess is provided in a horizontal frame so that connection members pass through the horizontal frame through the seating recess, thereby maximizing a height of the horizontal frame. A vertical frame cover is provided in a vertical frame to secure a height of the vertical frame side in each module space. A sealing member is provided in the seating recess to seal the seating recess. A double shielding structure, including a module space cover shielding each module space and a battery pack cover shielding a battery pack housing as a whole, is provided to maximize airtightness of the battery pack.