Shipping Package for Lithium Battery with Fire Suppression
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Solution Overview
Problem
Current shipping containers for high watt-hour lithium-ion batteries are costly, prone to failure during thermal runaway events due to uncontrolled pressure relief and ignition of gases, and require specialized training and permits, failing to adequately contain fires and heat generated by these batteries.
Innovation Solution
A shipping container design featuring an interior metal container filled with expanded glass granulate for fire suppression and a gas vent with a particulate screen and heat shield to control gas release, preventing ignition and over-pressurization, while using an exterior corrugated cardboard container for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the container is reinforced to contain the fire and high heat generated by thermal runaway, then fire containment is improved, but over-pressurization failure occurs
Solution Approach 1:
The container is divided into an inner fire-resistant chamber and an outer protective housing, with the fire containment function segmented from the structural containment function. This allows the inner chamber to be optimized for fire resistance while the outer structure handles mechanical strength requirements.
Solution Approach 2:
A heat-resistant intermediary material or layer is introduced between the battery and the container walls to mediate the thermal transfer. This intermediary protects the container structure from direct exposure to extreme temperatures while still containing the fire.
2Stress or pressure
If the container is adapted to release and mitigate pressure during thermal runaway, then pressure relief is improved, but structural failure occurs due to extreme heat and fire
Solution Approach 1:
Pressure relief vents and pathways are pre-designed and positioned in the container structure before thermal runaway occurs. These preliminary pressure management features allow controlled gas release without compromising structural integrity during the actual thermal event.
Solution Approach 2:
Different portions of the container have different properties: areas with pressure relief vents are designed with appropriate openings and shielding, while other areas maintain full structural integrity. The local quality of each section is optimized for its specific function during thermal runaway.
3Reliability
If expensive aluminum or steel cases are used for shipping, then safety and DOT compliance are improved, but manufacturing cost increases
Solution Approach 1:
The container uses composite construction combining fire-resistant materials (such as intumescent coatings or fire-retardant composites) with structurally adequate but less expensive materials. This composite approach achieves the required safety performance without the full cost of solid aluminum or steel construction.
Solution Approach 2:
The container design accepts that the packaging may be compromised during a thermal runaway event, so it uses more economical materials that are sufficient for their intended protective function but do not require the premium cost of heavy-duty metal construction. The container fulfills its safety purpose without being designed for indefinite reuse.
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 container effectively suppresses fires, controls gas venting to prevent ignition, and reduces the need for specialized training and permits, providing a safer and more economical solution for shipping high watt-hour lithium-ion batteries.
Implementation Method 1
free flowing expanded glass granulate having fire extinguishing properties
Implementation Method 2
cooperating heat shield in contact therewith to prevent ignition of the gas exiting the vent and to suppress the heat associated with the exiting gas
Implementation Method 3
vent for releasing gas from the container in a controlled manner
Data Source
AI summary
The invention is a shipping container for high watt-hour lithium-ion batteries, the container comprising an interior metal container and an exterior container within which the interior metal container is disposed, the interior metal container containing a free flowing expanded glass granulate having fire extinguishing properties, the interior metal container including a vent member for releasing gas from the interior container in a controlled manner, the vent having a cooperating heat shield in contact therewith to prevent ignition of gas exiting the vent and also suppress the heat associated with the exiting gas.