Rupture Disk Assembly for Battery Box Pressure Relief
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Solution Overview
Problem
Existing rupture disk designs for pressure relief in battery boxes are not cost-efficient for mass production and require complex installation processes, and they often lack the ability to withstand full vacuum conditions without additional support.
Innovation Solution
A three-layered rupture disk assembly consisting of a gasket layer, a reverse buckling metal disk layer with a domed portion and scored weakened area, and an outlet ring layer, which can be easily mounted using quick-threaded fasteners, allowing for adjustable burst pressure and robust vacuum resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional rupture disk designs are used, then pressure relief function is provided, but manufacturing cost increases and mass production efficiency decreases
Solution Approach 1:
The rupture disk is divided into multiple segments or zones with different thicknesses or material properties, allowing each segment to be manufactured independently or with different processes, thereby reducing overall manufacturing complexity and cost while maintaining mass production efficiency
Solution Approach 2:
The patent modifies key parameters such as disk thickness, material composition, or geometric configuration to optimize both manufacturing cost and production efficiency. By changing these parameters, the design achieves cost-effectiveness for mass production without sacrificing productivity
2Reliability
If complex installation processes are used, then secure mounting is achieved, but installation time and complexity increase
Solution Approach 1:
The rupture disk is pre-assembled with mounting flanges, sealing elements, or attachment mechanisms before installation. This preliminary preparation ensures secure mounting while significantly reducing on-site installation time and complexity, as the unit can be installed as a complete assembly rather than requiring complex step-by-step mounting procedures
Solution Approach 2:
The mounting system incorporates dynamic or adjustable features such as removable fasteners, flexible sealing mechanisms, or adjustable positioning elements that allow for quick installation and removal while maintaining secure mounting when installed, thereby improving ease of operation without compromising reliability
3Strength
If additional support structures are added, then vacuum resistance is improved, but device complexity and cost increase
Solution Approach 1:
The rupture disk incorporates a domed or curved geometry instead of a flat configuration. This curvature provides structural strength to withstand vacuum pressures without requiring additional support structures, thereby maintaining vacuum resistance while reducing device complexity and avoiding the need for extra components
Solution Approach 2:
The patent employs a thin-film or flexible shell structure that inherently resists vacuum pressures through its material properties and geometric design. This approach achieves the required vacuum resistance without adding complex support structures, as the thin film itself is engineered to withstand the pressure differential
4Adaptability or versatility
If burst pressure is fixed, then design simplicity is maintained, but adaptability to different pressure requirements decreases
Solution Approach 1:
The rupture disk design incorporates adjustable parameters such as variable thickness zones, selectable material options, or configurable geometric features that allow the burst pressure to be adjusted for different applications. This dynamic design capability enables adaptability to various pressure requirements while maintaining relatively simple overall device structure
Solution Approach 2:
By modifying key design parameters such as disk thickness, material composition, or hole pattern configuration, the same basic rupture disk design can be adapted to different burst pressure requirements. This parameter-based approach provides versatility without requiring completely different designs for each application
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 provides a cost-effective, easy-to-install rupture disk that effectively relieves pressure between a battery box's interior and exterior, ensuring reliable operation under vacuum conditions without additional support, with adjustable burst pressure settings.
Implementation Method 1
a second layer in the form of a reverse buckling disk having a disk flange, a domed portion and a weakened portion (e.g., score) on the dome that defines a disk burst pressure
Implementation Method 2
the weakened portion (e.g., score) on the dome that defines a disk burst pressure
Implementation Method 3
withstand full vacuum without any additional support
Implementation Method 4
a second layer in the form of a reverse buckling disk having a disk flange, a domed portion
Data Source
AI summary
A rupture disk is provided for relieving pressure between the interior of a battery box and the exterior of the battery box, the box having an outlet opening. A first layer provides a gasket which abuts the battery box, the gasket having a central opening which aligns with the battery box opening. A second layer is in the form of a reverse buckling disk having a disk flange, a domed portion and a weakened portion on the dome that defines a disk burst pressure, the second layer having concave and convex sides. A third layer that is an outlet ring that sandwiches the second layer in between the first and the third layer layers, the outlet ring having a central opening surrounded by an edge. A plurality of teeth on the third layer extend from said edge inwardly. A plurality of tabs are provided on the first and third layers.