Double-Walled Battery Pack Venting for Arc and Fire Risk
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Solution Overview
Problem
Existing energy storage devices in electric and hybrid vehicles face risks of electric arcs and subsequent fires due to gas release from malfunctioning electrochemical cells, which can lead to structural damage and oxygen ingress, exacerbated by complex and bulky designs.
Innovation Solution
A double-walled energy storage device with strategically positioned weak zones in the module envelopes and gas discharge chambers, along with valves that open under excess pressure, to safely vent gases away from electrical conductors and prevent oxygen ingress, while maintaining structural integrity and simplicity in manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a specific internal conduit is designed to convey gases to the outside, then gas discharge function is improved, but device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent merges the gas discharge function with the existing structural elements of the energy storage device. The double-walled structure's chamber serves dual purposes: providing structural support and serving as a gas discharge pathway. The weak zones in the envelope and openings in the inner wall are integrated into the module design rather than being separate components, thereby achieving gas discharge without increasing overall device complexity
Solution Approach 2:
The double-walled structure is designed to perform multiple functions simultaneously: it provides mechanical support, creates a gas discharge pathway, and maintains electrical isolation. The chamber between the inner and outer walls serves both as a structural element and as a conduit for gas discharge, eliminating the need for dedicated gas discharge components
2Use of energy by moving object
If electrochemical cells are assembled in series or parallel in an electrochemical module, then energy storage capacity is improved, but the risk of thermal runaway and electric arc formation increases
Solution Approach 1:
The patent segments the gas discharge pathway into multiple controlled zones: weak zones in the envelope, openings in the inner wall, and discharge openings in the outer wall. This segmentation allows controlled gas release at different stages, preventing uncontrolled thermal runaway while maintaining high energy storage capacity through series/parallel cell configurations
Solution Approach 2:
The double-walled structure with its intermediate chamber acts as a mediator between the electrochemical cells and the external environment. It provides a controlled interface for gas discharge, isolating the cells from direct exposure to oxygen while allowing safe pressure relief, thereby reducing thermal runaway risk without compromising energy storage capacity
3Reliability
If electrical conductors are spaced far enough apart to prevent electric arc, then safety is improved, but device volume increases
Solution Approach 1:
The inner wall with its openings serves as an intermediary barrier between gas sources and electrical conductors. It allows controlled gas discharge while maintaining physical separation from conductors, enabling closer conductor spacing without increasing electric arc risk or device volume
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 solution effectively reduces the risk of electric arcs and fires by ensuring controlled gas discharge, maintaining structural integrity, and simplifying manufacturing, thereby enhancing safety and reliability of energy storage devices in vehicles.
Implementation Method 1
the envelope being provided with at least one weak zone enabling gases contained inside the module to escape
Implementation Method 2
the structure comprising an inner wall, an outer wall and at least one chamber formed between the inner wall and the outer wall, the inner wall being provided with a set of openings positioned opposite the at least one weak zone of each module, the outer wall being provided with at least one discharge opening
Data Source
AI summary
An energy storage device includes a set of electrochemical modules and a housing enclosing the modules. The housing includes a double-walled structure. Each module includes electrochemical cells and an enclosure surrounding the electrochemical cells. The enclosure is provided with at least one weak zone capable of discharging gases contained inside the module. The structure includes an inner wall, an outer wall, and at least one chamber defined between the inner wall and the outer wall. The inner wall is provided with a set of openings positioned opposite the at least one weak zone of each module and the outer wall is provided with at least one discharge opening.