Battery Pack Beam Frame Venting for Flame Containment
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Solution Overview
Problem
Conventional battery packs fail to effectively suppress heat transfer and flame leakage between battery modules, leading to rapid collapse and spread of flames, posing safety risks.
Innovation Solution
A battery pack design featuring a flame blocking unit with a metal cover supported by a beam frame, equipped with a gas venting system and insulating material, to contain flames and manage pressure during thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If gas discharge holes are provided in the pack case to release internal pressure, then pressure buildup is prevented, but flames and high-temperature particles are discharged to the outside causing fire spread
Solution Approach 1:
A flame blocking unit is introduced as an intermediary component between the battery module and the external environment. This unit includes a flame blocking cover that selectively blocks flames and high-temperature particles while allowing gas to pass through, thus mediating between pressure release requirements and fire prevention needs
Solution Approach 2:
The flame blocking cover is designed with localized properties where different regions have different functions - some areas block flames completely while other areas allow gas passage. The cover material itself has specific thermal and mechanical properties tailored to withstand high temperatures while maintaining structural integrity
2Productivity
If battery modules are arranged closely to maximize space utilization, then productivity is improved, but heat transfer between adjacent modules occurs rapidly during thermal events
Solution Approach 1:
The internal space of the pack case is segmented into isolated compartments using beam frames and flame blocking units. Each battery module or group of modules is separated by these structural elements, creating independent zones that prevent heat and flame propagation between adjacent modules while maintaining compact overall dimensions
Solution Approach 2:
Beam frames and flame blocking covers serve as intermediary structures between adjacent battery modules. These intermediaries physically separate the modules and create thermal barriers that prevent direct heat transfer while allowing the pack to maintain high space utilization
3Ease of manufacture
If the pack case structure is simplified to reduce manufacturing complexity, then ease of manufacture is improved, but the ability to suppress flame spread and heat transfer is reduced
Solution Approach 1:
The beam frame structure is designed to serve multiple functions simultaneously: it provides structural support for the pack case, acts as a thermal barrier between modules, supports the flame blocking units, and facilitates modular assembly. This multi-functionality reduces the need for additional specialized components while maintaining flame suppression capabilities
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 delays pack collapse and minimizes flame leakage, protecting adjacent modules and reducing external fire spread.
Implementation Method 1
a flame blocking unit connected to the beam frame and configured to cover the corresponding battery module at a lower portion of the pack cover to block a flame emitted from the battery module
Implementation Method 2
If a specific battery module inside the battery pack ignites and gas is generated, the gas may be discharged to the outside through the gas discharge hole, so that the internal pressure of the battery pack does not rapidly increase
Data Source
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AI summary
Disclosed is a battery pack, which includes a plurality of battery modules; a pack tray having an open upper portion and an inner space capable of accommodating the plurality of battery modules, the pack tray including a beam frame arranged between the battery modules adjacent to each other and partitioning the inner space; a pack cover covering the upper portion of the pack tray; and a flame blocking unit connected to the beam frame and provided to cover the corresponding battery module at a lower portion of the pack cover to block a flame emitted from the battery module.