Battery Pack Spark Prevention Mesh for Thermal Runaway Safety
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Solution Overview
Problem
Conventional battery packs face the risk of explosions and fires due to the discharge of spark particles during thermal runaway, as they lack a mechanism to selectively release high-temperature gases while preventing spark particles from escaping to oxygen-rich environments.
Innovation Solution
A battery pack design featuring a pack case with discharge holes and an upper case equipped with a mesh structured spark prevention member, where the mesh holes are sized between 0.1 mm to 0.43 mm to allow gas passage while blocking spark particles, and the spark prevention member is positioned to cover discharge holes and spaced apart from the side beam to create additional pathways for gas discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a gas discharge path is provided on the side of the battery pack to release high-temperature gas during thermal runaway, then the internal pressure can be reduced, but spark particles can escape through the discharge path to the oxygen-dense environment outside causing explosion risk
Solution Approach 1:
A mesh structured spark prevention member is introduced as an intermediary component between the internal cell assembly and the external environment. This mesh member allows high-temperature gas to pass through while blocking spark particles, thus mediating the conflict between pressure relief and spark containment. The mesh structure acts as a selective filter that permits gas flow but retards particle escape.
Solution Approach 2:
The spark prevention member is specifically positioned at the lower end of the upper case, which corresponds to the discharge hole location on the pack case. This localized placement ensures that the mesh structure is precisely where the gas discharge occurs, creating a targeted solution that addresses the harmful effect at the critical location without affecting other parts of the battery pack.
2Object-affected harmful factors
If the mesh hole diameter is reduced to block spark particles, then spark prevention effectiveness increases, but gas discharge efficiency decreases
Solution Approach 1:
The patent specifies a precise parameter range for the mesh hole diameter (0.1 mm to 0.43 mm) to optimize the balance between spark particle blocking and gas discharge efficiency. By carefully selecting and controlling this dimensional parameter, the mesh structure achieves effective spark retention while maintaining sufficient gas flow capacity to relieve internal pressure during thermal runaway events.
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 design effectively prevents explosions and fires by ensuring smooth gas discharge while inhibiting spark particles from escaping, thereby enhancing safety in battery packs.
Implementation Method 1
an upper case having a mesh structured spark prevention member corresponding to the discharge hole, wherein the mesh holes have an average diameter of 0.1 mm to 0.43 mm
Data Source
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AI summary
Disclosed herein relates to a battery pack accommodating a plurality of cell assemblies, including: a pack case in which a cell assembly is seated; an upper case coupled to the pack case to cover an upper part of a cell assembly seated inside the pack case; and at least one spark prevention member comprising circular mesh holes and provided at the lower end of the upper case, wherein the pack case includes at least one discharge hole on a side part communicating with the interior space, the spark prevention member is provided at a location corresponding to the discharge hole of the pack case, and the mesh holes have an average diameter of 0.1 mm to 0.43 mm.