Battery Pack Discharge Path for Thermal Runaway Gas Ejection
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Solution Overview
Problem
Battery packs face safety concerns due to potential fires or explosions from battery cells, which can damage internal and external components and pose risks to users, as existing solutions do not effectively manage the discharge of high-temperature gases and flames.
Innovation Solution
A battery pack design featuring a cell frame, guide covers, and a pack housing with a discharge portion that allows internal materials to be directed and discharged externally through a moving passage, utilizing a thinner discharge portion that self-perforates under high temperatures, and additional features like screen ribs and cover films to control the direction and containment of ejected materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery cells are enclosed in a sealed housing, then structural integrity and protection are improved, but safety against fire or explosion is worsened due to accumulation of high-temperature gas and flame
Solution Approach 1:
The patent extracts the harmful high-temperature gas and flame from the enclosed housing by providing a dedicated discharge portion that allows these substances to be ejected outward. The guide cover and moving passage work together to direct the ejected material away from internal components, effectively removing the harmful accumulation problem while maintaining the protective enclosure.
Solution Approach 2:
The patent converts the harmful high-temperature gas and flame into a beneficial ejection mechanism. By designing the discharge portion with thinner thickness and positioning it to face the moving passage, the housing utilizes the pressure and direction of the ejected material to automatically open a discharge path, transforming the harmful thermal runaway byproduct into a self-regulating safety feature.
2Reliability
If additional safety components are added to manage fire and gas discharge, then safety against thermal runaway is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The guide cover serves multiple functions: it covers the battery cells for protection, forms the moving passage to direct ejected material, and works with the discharge portion to enable controlled discharge. The discharge portion itself serves both as a structural component of the housing and as the safety discharge mechanism, eliminating the need for separate safety valves or vents.
Solution Approach 2:
The discharge portion is designed with thinner thickness compared to other portions of the housing, allowing it to automatically deform or open under the pressure of high-temperature gas and flame during thermal runaway. This self-activating mechanism eliminates the need for external sensors, actuators, or control systems to trigger the discharge function.
3Strength
If the housing is made uniformly thick for structural strength, then mechanical protection is improved, but ability to self-perforate under high temperature is worsened
Solution Approach 1:
The housing exhibits non-uniform thickness distribution, with the discharge portion having thinner thickness compared to other portions. This local variation allows the discharge portion to be more responsive to thermal expansion and pressure from high-temperature gas, enabling it to deform or open automatically during thermal runaway while other thicker portions maintain overall structural integrity and mechanical protection.
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
This design effectively directs and discharges high-temperature gases and flames away from internal components and external devices, enhancing safety by minimizing damage and reducing manufacturing costs without additional components.
Implementation Method 1
the discharge portion may be formed to have a relatively thin thickness compared to other portions adjacent to a portion of the pack housing
Implementation Method 2
one or more guide covers configured to cover at least one side of the plurality of battery cells, at least a portion of which is spaced apart from the cell frame by a predetermined distance to form a moving passage through which the internal material moves
Data Source
AI summary
A battery pack includes a plurality of battery cells, each configured to discharge an internal material to an outside by an internal pressure when the internal pressure is greater than a predetermined pressure; a cell frame configured to accommodate the plurality of battery cells so that the internal material is discharged in at least one direction; one or more guide covers configured to cover at least one side of the plurality of battery cells, at least a portion of the one or more guide covers is spaced apart from the cell frame by a predetermined distance to form a moving passage through which the internal material moves; and a pack housing having an accommodation space configured to accommodate the cell frame therein and a discharge portion such that a portion facing a distal end of the moving passage is configured to be perforated by the internal material.