Battery Vent Flame Arrestor Mesh for Thermal Runaway Containment

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Solution Overview

Problem

Existing vehicle battery cell packs are vulnerable to thermal runaway events, where flaming gases can spread through vents, potentially propagating the event to neighboring cells, and there is a need to minimize this propagation.

Innovation Solution

A flame arrestor with a thermally conductive surface and mesh panel is integrated with the battery cell assembly, featuring openings to redirect heat and trap particulate matter, coupled with a thermal mass to dissipate heat and prevent flame spread.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vents are provided to prevent condensation and corrosion, then battery cell protection is improved, but flame spread to neighboring cells increases

Engineering Contradiction:

Improvebattery cell protectionVSAvoidflame spread

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The flame arrestor segments the vent opening into multiple smaller passages through its mesh structure, allowing vapor passage while blocking flame propagation. The mesh panel divides the continuous vent path into discrete segments that prevent flame front continuity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flame arrestor acts as an intermediary component between the battery cell vent and the external environment. It mediates the flow path by allowing beneficial vapor discharge while blocking harmful flame propagation through its thermally conductive mesh structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a flame arrestor is added to block flame spread, then flame propagation is prevented, but device complexity increases

Engineering Contradiction:

Improveflame propagationVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The flame arrestor performs multiple functions simultaneously: it blocks flame propagation, redirects heat away from neighboring cells, traps particulate matter, and maintains vapor discharge capability. This multi-functionality reduces the need for additional separate safety components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The flame arrestor utilizes a mesh panel with controlled porosity that allows vapor passage while blocking flame fronts. The porous structure provides flame arrestment through capillary effects and thermal conduction without requiring solid sealing.

Inventive Principle:

Principle #31Porous materials

3Reliability

If mesh panel with small openings is used to trap particulate matter, then particulate containment is improved, but airflow resistance increases

Engineering Contradiction:

Improveparticulate containmentVSAvoidairflow resistance

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The flame arrestor combines mesh panel material with endothermic flame retardant coating to create a composite structure. This composite provides both particulate filtration and thermal management while maintaining airflow characteristics.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The mesh panel parameters (opening size, wire diameter, mesh density) are optimized to balance particulate containment with airflow resistance. The opening dimensions are specifically selected to trap particulate matter while allowing sufficient vapor discharge.

Inventive Principle:

Principle #35Parameter changes

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 flame arrestor effectively redirects heat and traps particulates, minimizing the risk of thermal runaway and preventing flame propagation, while maintaining airflow and cooling the battery cells.

Implementation Method 1

The at least one flame arrestor has a thermally conductive surface area and includes a first set of openings. The first set of openings are configured to redirect heat from the one or more battery cells within the cavity of the housing.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the mesh panel may include an endothermic flame retardant material

Methodology Applied

Scientific EffectEndothermic reaction: Endothermic Reaction

Implementation Method 3

a thermal mass that is thermally coupled to the at least one flame arrestor

Methodology Applied

Scientific EffectThermal energy storage: Thermal Energy Storage

Implementation Method 4

the battery cells may include particulate matter and the mesh panel of the at least one flame arrestor may be configured to trap the particulate matter within the cavity of the housing

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Data Source

PatentUS20250391993A1Flame arrestor for battery cell group assembly

Publication Date: 2025.12.25 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A battery cell group assembly for a vehicle includes a housing including a plurality of panels defining a cavity and one or more battery cells disposed within the cavity of the housing. One or more thermal barriers are coupled to each of the one or more battery cells, and vents are defined proximate to the one or more battery cells. The battery cell group assembly also includes at least one flame arrestor disposed over the vents. The at least one flame arrestor has a thermally conductive surface area and includes a first set of openings. The first set of openings are configured to redirect heat from the one or more battery cells within the cavity of the housing. The battery cell group assembly further includes a thermal mass that is thermally coupled to the at least one flame arrestor.