Composite Battery Enclosure With Fire Hose Connection for Li-Ion Fires
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Solution Overview
Problem
Existing battery containment constructs for electric and hybrid vehicles are heavy due to metal materials, prone to corrosion, and have manufacturing inefficiencies, while also posing risks from lithium-ion battery fires that are difficult to extinguish, necessitating a lightweight, durable, and fire-resistant solution with improved manufacturing throughput and effective fire inhibition.
Innovation Solution
A battery containment construct using composite materials with a fire department connection, featuring a fastening system and integrated fire department connections for fluid communication with a fire inhibitor, providing impact resistance, fire resistance, and fluid penetration prevention, and incorporating a one-way fire inhibitor exhaust valve for efficient fire suppression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal containment constructs are used for battery cells, then fire resistance and protection are improved, but weight increases and corrosion resistance deteriorates
Solution Approach 1:
The patent employs composite materials consisting of a thermoplastic matrix reinforced with heat-resistant fiber reinforcement (such as glass, carbon, or aramid fibers) to create a containment construct that achieves fire resistance comparable to metal while significantly reducing weight. The composite structure maintains structural integrity at elevated temperatures without the corrosion and weight penalties of metal construction.
2Strength
If metal bolts and nuts are used to join composite housing portions, then connection strength is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (metal bolts and nuts requiring drilling, threading, and assembly) with integrated snap-fit or injection-molded interlocking features directly formed in the composite housing portions. This substitution maintains connection strength while eliminating multiple manufacturing steps, reducing assembly time, and improving production throughput.
3Weight of moving object
If composite materials are used for containment construct, then weight is reduced, but impact resistance and structural strength deteriorate
Solution Approach 1:
The patent utilizes a composite material system where a thermoplastic matrix is reinforced with a three-dimensional network of heat-resistant fibers (glass, carbon, or aramid). This composite architecture provides both weight reduction and enhanced impact resistance through fiber reinforcement that distributes and absorbs impact forces throughout the structure, achieving a strength-to-weight ratio superior to traditional metal construction.
4Reliability
If fire inhibitor is supplied continuously into the cavity, then fire inhibition effectiveness is improved, but fluid loss and environmental contamination increase
Solution Approach 1:
The patent incorporates a one-way exhaust valve that maintains a sealed environment around the battery cells during normal operation, preventing fire inhibitor leakage. The valve remains closed under normal pressure conditions, containing the fire inhibitor within the cavity where it can be reused, and only opens when pressure differential exceeds a threshold (such as during fire conditions), allowing controlled exhaust while minimizing fluid loss and environmental contamination.
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 offers a lightweight, durable battery containment system that effectively inhibits lithium-ion fires, enhances manufacturing efficiency, and prevents fluid penetration, thereby reducing the risk of uncontrollable vehicle fires and improving passenger safety during accidents.
Implementation Method 1
cooling the cavity with the fire inhibitor
Implementation Method 2
supplying the fire inhibitor from the source through the first hose into the cavity, cooling the cavity with the fire inhibitor, and inhibiting the fire
Data Source
AI summary
A battery containment construct including a first housing portion, a second housing portion complimentary to the first housing portion to define a cavity therebetween, and a fastening system to join the first housing portion to the second housing portion. The cavity defined therebetween being adapted to retain a plurality of reactive metal battery cells therein. The battery containment construct further including at least one fire department connection joined to at least one of the first housing portion or the second housing portion and in fluid communication with the cavity so enable connection of a fire hose to the battery containment construct for providing a fire inhibitor to the reactive metal battery cells in order to extinguish or contain a fire.