Battery Pack Hinged Flap Venting for Thermal Event Gas Release
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Solution Overview
Problem
Existing battery assemblies in electrified vehicles lack an efficient mechanism to manage and vent gases generated during thermal events, which can exacerbate these events and pose risks to the battery cells.
Innovation Solution
A battery assembly with a hinged flap configured within the frame, allowing vent gas to be released away from the battery cells while maintaining structural integrity and minimizing the risk of further thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a vent opening is provided in the battery pack frame, then vent gases can be released during thermal events, but vent gases may flow back towards the battery cells and exacerbate thermal issues
Solution Approach 1:
The patent applies the dynamics principle by providing a movable flap instead of a fixed vent opening. The flap can rotate between a closed position (resisting gas flow toward cells) and an open position (allowing gas escape). This dynamic mechanism resolves the contradiction by adapting the vent structure's state based on operational requirements, allowing the system to simultaneously protect cells from thermal damage while enabling necessary gas venting during thermal events.
Solution Approach 2:
The vent structure is segmented into a flap portion and a hinge portion, allowing independent functionality. The flap can move relative to the frame while remaining attached via the hinge, enabling controlled gas flow management. This segmentation allows the vent opening to perform its release function while the flap provides protective capability, resolving the contradiction between venting and protection.
2Object-affected harmful factors
If a hinged flap is used to control vent gas flow, then gas can be directed away from battery cells, but the device complexity increases
Solution Approach 1:
The flap mechanism is designed to be self-operating, utilizing the natural pressure differential created during thermal events to automatically open and close. The flap rotates about the hinge in response to gas pressure without requiring external actuation or control systems. This self-service approach provides the protective function while minimizing the addition of complex control mechanisms.
Solution Approach 2:
The flap and hinge are integrated as a single structural unit with the frame, where the hinge serves both as a structural connector and as the rotation mechanism. This merging of functions reduces the number of separate components needed, thereby reducing overall device complexity while maintaining the protective capability.
3Ease of operation
If the second gap extends through the entire thickness of the frame, then the flap can rotate freely, but vent gas can flow through the gap towards the battery cells
Solution Approach 1:
The gap geometry is designed with local quality variations: the second gap extends only partially through the frame thickness (not fully), creating a restricted opening that allows flap rotation while blocking gas flow toward cells. This localized geometric modification resolves the contradiction by providing sufficient clearance for rotation while maintaining protection against harmful gas flow.
Solution Approach 2:
The partially-extending second gap acts as an intermediary structure between the flap rotation requirement and the gas flow protection requirement. It provides the necessary mechanical clearance for rotation while simultaneously serving as a barrier to gas flow, mediating between the two conflicting requirements without requiring additional components.
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 hinged flap effectively directs vent gases away from the battery cells, mitigating thermal events and reducing the risk of damage, thereby enhancing safety and performance.
Implementation Method 1
the flap rotated in a direction away from the plurality of battery cells to form a vent gas opening in which vent gas can flow through the frame via the vent gas opening
Implementation Method 2
in the resting position, the flap is configured to resist vent gas flowing through the flap in a direction toward the plurality of battery cells
Data Source
AI summary
This disclosure relates to a battery assembly of an electrified vehicle, and in particular to a battery pack with a hinged flap configured to release vent gas. In some aspects, the techniques described herein relate to a battery assembly for an electrified vehicle, including: a battery array including a plurality of battery cells; an enclosure assembly surrounding the battery array; and a frame within the enclosure assembly, wherein the frame includes a flap, wherein the flap includes a perimeter having a first portion along which a first gap is present between the flap and the frame throughout an entirety of a thickness of the frame, and a second portion configured as a hinge of the flap and along which a second gap is present only partially through the thickness, wherein the second gap is formed in a side of the frame facing the plurality of battery cells.