Abstract:
A thermal event suppression system and method can include: a fire extinguishing media case including fire extinguishing media enclosed therein; a conduit fluidly connected to the fire extinguishing media case; a battery pack having a battery pack housing therearound, and the conduit coupling the fire extinguishing media case and the battery pack housing; a valve coupled to the conduit, the valve for controlling the flow of the fire extinguishing media; a metallic filament thermal event detector in direct contact with the valve, the valve configured to open based on a high temperature reading from the metallic filament thermal event detector, and the metallic filament thermal event detector running the whole length of the battery pack; and a nozzle within battery pack housing for dispensing the fire extinguishing media within the battery pack housing.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This is a Continuation-in-Part of U.S. patent application Ser. No. 13/442,883 filed Apr. 10, 2012, and claims the benefit of priority to all common subject matter. The content of this application is incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure relates to thermal event suppression and more particularly relates to thermal event suppression in high voltage batteries used in such things as hybrid and electric vehicles. 
       BACKGROUND 
       [0003]    Modernly, with the increased costs of fuel and the rising environmental concerns, many individuals now choose to drive automobiles such as hybrid and electric vehicles (hereafter referred together as “hybrid”). Hybrid vehicles have become very popular as an alternative to regular gasoline traditional based vehicles. 
         [0004]    With the advancement of technology, many hybrid vehicles contain high voltage batteries which enable them to perform their function of powering hybrid vehicles. Contained within high voltage batteries are cells that typically contain chemical fluids and materials, such as gels or dry materials, which store and release energy in the form of electricity to provide power to the vehicle. 
         [0005]    In certain cases involving accidents resulting in impact, the high voltage batteries may become damaged whereby the chemical fluids and materials previously residing in the high voltage battery cells are exposed to the environment and may cause a highly dangerous situation due to its flammable composition. 
         [0006]    Solutions have been long sought but prior developments have not taught or suggested any complete solutions, and solutions to these problems have long eluded those skilled in the art. Thus, there remains a considerable need for devices and methods that can safely, quickly, and efficiently contain and stop fires within high voltage battery compartments. 
       SUMMARY 
       [0007]    A thermal suppression system and methods, providing significantly safer, quicker, and more efficient containment and cessation of fires within high voltage battery compartments, are disclosed. The thermal event suppression system and method can include: a fire extinguishing media case including fire extinguishing media enclosed therein; a conduit fluidly connected to the fire extinguishing media case; a battery pack having a battery pack housing therearound, and the conduit coupling the fire extinguishing media case and the battery pack housing; a valve coupled to the conduit, the valve for controlling the flow of the fire extinguishing media; a metallic filament thermal event detector in direct contact with the valve, the valve configured to open based on a high temperature reading from the metallic filament thermal event detector, and the metallic filament thermal event detector running the whole length of the battery pack; and a nozzle within battery pack housing for dispensing the fire extinguishing media within the battery pack housing. 
         [0008]    Other contemplated embodiments can include objects, features, aspects, and advantages in addition to or in place of those mentioned above. These objects, features, aspects, and advantages of the embodiments will become more apparent from the following detailed description, along with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The thermal suppression system is illustrated in the figures of the accompanying drawings which are meant to be exemplary and not limiting, in which like reference numerals are intended to refer to like components, and in which: 
           [0010]      FIG. 1  is a first embodiment where the valve and the thermal event detector inside of the battery housing. 
           [0011]      FIG. 2  is a second embodiment where the valve and the thermal event detector outside of the battery housing. 
           [0012]      FIG. 3  is a third embodiment using a control unit, where the thermal sensor is outside of the battery housing. 
           [0013]      FIG. 4  is a fourth embodiment using a control unit, where the thermal sensor is inside of the battery housing. 
           [0014]      FIG. 5  is a fifth embodiment in an isometric view. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]    In the following description, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration, embodiments in which the thermal suppression system may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the thermal suppression system. 
         [0016]    The thermal suppression system is described in sufficient detail to enable those skilled in the art to make and use the thermal suppression system and provide numerous specific details to give a thorough understanding of the thermal suppression system; however, it will be apparent that the thermal suppression system may be practiced without these specific details. 
         [0017]    In order to avoid obscuring the thermal suppression system, some well-known system configurations are not disclosed in detail. Likewise, the drawings showing embodiments of the system are semi-diagrammatic and not to scale and, particularly, some of the dimensions are for the clarity of presentation and are shown greatly exaggerated in the drawing FIGs. 
         [0018]    It will be appreciated that such block components may be realized by any number of hardware, software,  16  and/or firmware components configured to perform the specified functions. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships and/or physical couplings between the various elements. 
         [0019]    Referring now to  FIG. 1 , therein is shown a first embodiment where the valve and the thermal event detector inside of the battery housing. The integrated thermal event suppression system is shown comprising a battery pack  1 , housing of the battery pack  5 , a fire extinguisher media case  102 , a fire extinguishing media  104 , a nozzle  106 , a conduit  108 , a thermal event detector  110 , and a valve, or flow control device for embodiments using a control unit  116 . 
         [0020]    In this drawing view, the valve, or flow control device for embodiments using the control unit  116  and metallic filament (not shown) are positioned inside the housing of the battery pack  5 . The control unit  116  can be an electrical or a thermal control unit. The thermal event suppression system comprises a fire extinguishing media case  102  which contains a fire extinguishing media  104  that has properties and features that are able to put out thermal events such as a fire resulting from the high voltage battery being damaged or malfunctioning. 
         [0021]    It is contemplated that the fire extinguishing media  104  can consists of at least one of a class A type, class B type, class C type, and class D type fire extinguisher. The fire extinguishing media can be comprised of Halon or Halon-like properties. 
         [0022]    In the present embodiment, the valve  112  is coupled to a nozzle  106  which is adapted to spray or release the fire extinguishing media  104  upon the internal components of the housing of the battery pack  5 . A conduit  108  fluidly connects the fire extinguishing media case  102  to the nozzle  106  to allow for proper transfer of the fire extinguishing media  104  from the fire extinguishing case  102  to the housing of the battery pack  5 . 
         [0023]    The thermal event detector  110  can be a metallic filament that controls the opening of the valve  112  based on a temperature surrounding the metallic filament. In one practicing embodiment, once the temperature surrounding the metallic filament reaches a certain temperature, the metallic filament  111  is melted and the valve  112  on the thermal event detector  110  is opened resulting in the flow of the fire extinguishing media  104  from the fire extinguishing case  102  allowing the nozzle  106  to spray the fire extinguishing media  104  into the housing of the battery pack  5 . 
         [0024]    Referring now to  FIG. 2 , therein is shown a second embodiment where the valve and the thermal event detector outside of the battery housing. The valve or flow control device for embodiments using the control unit  116  and metallic filament (not shown), can be positioned outside the housing of the battery pack  5 . 
         [0025]    The integrated thermal event suppression system is shown comprising a battery pack  1 , housing of the battery pack  5 , a fire extinguisher media case  102 , a fire extinguishing media  104 , a nozzle  106 , a conduit  108 , a thermal event detector  110 , and a valve, or flow control device for embodiments using the control unit  116 . 
         [0026]    The thermal event suppression system comprises a fire extinguishing media case  102  which contains a fire extinguishing media  104  that has properties and features that are able to put out thermal events such as a fire resulting from the high voltage battery being damaged. The fire extinguishing media  104  can consists of at least one of a class A type, class B type, class C type, and class D type fire extinguisher. 
         [0027]    The fire extinguishing media can be comprised of Halon or Halon-like properties. In the present embodiment, the valve  112  is coupled to a nozzle  106  which is adapted to spray or release the fire extinguishing media  104  upon the internal components of the housing of the battery pack  5 . A conduit  108  fluidly connects the fire extinguishing media case  102  to the nozzle  106  to allow for proper transfer of the fire extinguishing media  104  from the fire extinguishing case  102  to the housing of the battery pack  5 . 
         [0028]    The thermal event detector  110  can be a metallic filament that controls the opening of the valve  112  based on a temperature surrounding the metallic filament. Once the temperature surrounding the metallic filament reaches a certain temperature, the metallic filament  111  is melted and the valve  112  on the thermal event detector  110  is opened resulting in the flow of the fire extinguishing media  104  from the fire extinguishing case  102  allowing the nozzle  106  to spray the fire extinguishing media  104  into the housing of the battery pack  5 . 
         [0029]    Referring now to  FIG. 3 , therein is shown a third embodiment using the control unit  116 , where the thermal sensor  114  is outside of the battery pack housing  5 . The thermal event suppression system is shown comprising a fire extinguishing media case  102  which contains a fire extinguishing media  104  that has properties and features that are able to put out thermal events such as a fire resulting from the high voltage battery being damaged or malfunctioning, for example by an internal short. 
         [0030]    The fire extinguishing media  104  can consists of at least one of a class A type, class B type, class C type, and class D type fire extinguisher. The fire extinguishing media can be comprised of Halon or Halon-like properties. 
         [0031]    The valve  112  is coupled to a nozzle  106  which is adapted to spray or release the fire extinguishing media  104  upon the internal components of the battery pack housing  5 . A conduit  108  fluidly connects the fire extinguishing media case  102  to the nozzle  106  to allow for proper transfer of the fire extinguishing media  104  from the fire extinguishing case  102  to the battery pack housing  5 . 
         [0032]    The thermal sensor  114  can be coupled to the control unit  116 . The control unit  116  can be a thermal or electrical control unit. The thermal sensor  114  triggers the control unit  116  when the thermal sensor  114  senses a temperature over a specific threshold making the valve or flow control device for embodiments using the control unit  116  opening resulting in the flow of the fire extinguishing media  104  from the fire extinguishing case  102  allowing the nozzle  106  to spray the fire extinguishing media  104  into the battery pack housing  5 . 
         [0033]    In addition to the thermal sensor  114 , which can trigger the control unit  116  to open the valve  112  and dispense the fire extinguishing media  104  into the battery pack housing  5 ; the battery pack housing  5  is further shown with the thermal event detector  110  in the form of a metallic filament  111 . 
         [0034]    The thermal event detector  110  is depicted extending from the valve  112  into the battery pack housing  5 . further the thermal event detector  110  is shown to extend from one end of the battery pack housing  5  to the other and in this configuration it has been discovered to enable the detection of a thermal event at any cross-section within the battery pack housing  5  providing enhanced thermal protection. 
         [0035]    It is contemplated that the valve  112  could be placed within the battery pack housing  5  and the thermal event detector  110  could extend only within the battery pack housing  5  and not extend outside the battery pack housing  5  in order to reduce ambient exposure. Further, it is contemplated that the thermal event detector  110  can extend to other locations within the battery pack housing  5  by bending around batteries  302  within the battery pack housing  5 . 
         [0036]    Illustratively, it is contemplated that the thermal event detector  110  can be positioned within the battery pack housing  5  so that each battery cell  302  within the battery pack housing  5  can be in direct contact with the thermal event detector  110 . Alternatively, it is contemplated that the thermal event detector  110  can be positioned within the battery pack housing  5  so as to be located at venting locations along the individual batteries  302  within the battery pack housing  5 . 
         [0037]    The thermal event detector  110  is shown as a metallic filament  111  within a tube. Alternatively, the metallic strip  111  can be replaced with a glass tube sensitive and reactive to temperature. The metallic filament  111  can melt, fracture, or deform based on heat. Illustratively, the metallic filament  111  can detect thermal changes by melting, fracturing, or deforming in the presence of heat beyond the melting, fracturing, or deforming point of the metallic filament  111 . In one contemplated embodiment, the metal filament can be a braided wire with  3  strands. It is contemplated that the metallic filament  111  can alternatively be a glass bulb. 
         [0038]    When the metallic filament  111  melts, the valve  112  will open to dispense the fire extinguishing media  104 . The fire extinguishing media  104  can flow from the conduit  108  located on a high pressure side of the valve  112 , through the valve  112 , into the conduit  108  coupled to a low pressure side of the valve  112  and into the nozzle  106 . 
         [0039]    Once the fire extinguishing media  104  is forced into the nozzle  106 , the fire extinguishing media  104  can be dispensed into the battery pack housing  5 . In the present illustrative embodiment, the nozzle  106  is depicted as a manifold extending laterally within the battery pack housing  5 . Other contemplated implementations can include the nozzle  106  being highly localized and including a deflector capable of dispensing the fire extinguishing media  104  throughout the battery pack housing  5 . 
         [0040]    It has been discovered that the implementation of the thermal event detector  110  as a metallic filament  111  detecting temperature changes without sampling the air or gas within the battery pack housing  5  provides many important improvements. For example, one important benefit of detecting temperature with the metallic filament  111  without sampling air within the battery pack housing  5  arrises from the cooling effect sampling air has. When the air within the battery pack housing  5  is sampled the air within the battery pack housing  5  is cooled and reduces the operating temperature of the batteries  302  within the battery pack housing  5 . 
         [0041]    Reducing the operating temperature within the battery pack housing  5  requires complicated engineering solutions; however, when the air within the battery pack housing  5  is not cooled by air sampling but instead is temperature detected with the metallic filament  111 , the batteries  302  within the battery pack housing  5  are permitted to operate passively within the thermal operating temperature band because the climate within the battery pack housing  5  is not altered by the thermal event detector  110 . 
         [0042]    Another important improvement discovered by implementing the thermal event detector  110  as the metallic filament  111  comes from the reduced complexity of air sampling methods which require the utilization of pipes, valves, springs, and levers. These additional components result in additional points of failure, which the thermal event detector  110  when implemented as the metallic filament  111  simply does not require. 
         [0043]    Yet another important improvement discovered when implementing the thermal event detector  110  as the metallic filament  111  is the ability to quickly implement the thermal event detector  110  with any existing battery  302 . It is contemplated that the thermal event detector  110  as shown and described with regard to  FIG. 3  can be implemented with the designs and components of the other embodiments without departing from the disclosure and those of ordinary skill in the art would recognize that the arrangement of components such as the thermal sensor  114 , the valve  112 , the control unit  116 , the conduit  108 , along with others could be implemented with the thermal event detector  110  as shown in  FIG. 3 . 
         [0044]    Referring now to  FIG. 4 , therein is shown a third embodiment using the control unit  116 , where the thermal sensor  114  is inside of the battery pack housing  5 . The thermal event suppression system is shown comprising a fire extinguishing media case  102  which contains a fire extinguishing media  104  that has properties and features that are able to put out thermal events such as a fire resulting from the high voltage battery being damaged or malfunctioning. 
         [0045]    The fire extinguishing media  104  can consists of at least one of a class A type, class B type, class C type, and class D type fire extinguisher. The fire extinguishing media can be comprised of Halon or Halon-like properties. 
         [0046]    The valve  112  is coupled to multiple nozzles  106  which are adapted to spray or release the fire extinguishing media  104  upon the internal components of the battery pack housing  5 . Multiple conduits  108  fluidly connects the fire extinguishing media case  102  to the nozzles  106  to allow for proper transfer of the fire extinguishing media  104  from the fire extinguishing case  102  to the battery pack housing  5 . It has been discovered that the multiple nozzles  106  and the multiple conduits  108  can be utilized with larger batteries  302  or when a higher volume of the fire extinguishing media  104  is required. 
         [0047]    The thermal sensor  114  can be coupled to the control unit  116 . The control unit  116  can be a thermal or electrical control unit. The thermal sensor  114  triggers the control unit  116  when the thermal sensor  114  senses a temperature over a specific threshold making the valve or flow control device for embodiments using the control unit  116  opening resulting in the flow of the fire extinguishing media  104  from the fire extinguishing case  102  allowing the nozzles  106  to spray the fire extinguishing media  104  into the battery pack housing  5 . 
         [0048]    In addition to the thermal sensor  114 , which can trigger the control unit  116  to open the valve  112  and dispense the fire extinguishing media  104  into the battery pack housing  5 ; the battery pack housing  5  is further shown with the thermal event detector  110  in the form of a metallic filament  111 . 
         [0049]    The thermal event detector  110  is shown to extend fully across all of the batteries  302  within the battery pack housing  5 . It has been discovered that the extension of the thermal event detector  110  fully across the batteries  302  enables the detection of a thermal event at any point along the batteries  302 . 
         [0050]    The valve  112 , the fire extinguishing media case  100 , and the conduits  108  are depicted within the battery pack housing  5  and the thermal event detector  110  is shown extending only within the battery pack housing  5  and not extend outside the battery pack housing  5  in order to reduce ambient exposure. Further, it is contemplated that the thermal event detector  110  can extend to other locations within the battery pack housing  5  by bending around batteries  302  within the battery pack housing  5 . 
         [0051]    Illustratively, it is contemplated that the thermal event detector  110  can be positioned within the battery pack housing  5  so that each battery cell  302  within the battery pack housing  5  can be in direct contact with the thermal event detector  110 . Alternatively, it is contemplated that the thermal event detector  110  can be positioned within the battery pack housing  5  so as to be located at venting locations along the individual batteries  302  within the battery pack housing  5 . 
         [0052]    The thermal event detector  110  is shown as a metallic filament  111  within a tube. The metallic filament  111  can detect thermal changes by melting in the presence of heat beyond the melting point of the metallic filament  111 . 
         [0053]    When the metallic filament  111  melts, the valve  112  will open to dispense the fire extinguishing media  104 . The fire extinguishing media  104  can flow from the conduits  108  located on a high pressure side of the valve  112 , through the valve  112 , into the conduits  108  coupled to a low pressure side of the valve  112  and into the nozzles  106 . 
         [0054]    Once the fire extinguishing media  104  is forced into the nozzles  106 , the fire extinguishing media  104  can be dispensed into the battery pack housing  5 . In the present illustrative embodiment, the nozzles  106  are depicted as multiple manifolds extending laterally within the battery pack housing  5 . Other contemplated implementations can include the nozzles  106  being highly localized and including deflectors capable of dispensing the fire extinguishing media  104  throughout the battery pack housing  5 . 
         [0055]    It has been discovered that the implementation of the thermal event detector  110  as a metallic filament  111  detecting temperature changes without sampling the air or gas within the battery pack housing  5  provides many important improvements. For example, one important benefit of detecting temperature with the metallic filament  111  without sampling air within the battery pack housing  5  arrises from the cooling effect sampling air has. When the air within the battery pack housing  5  is sampled the air within the battery pack housing  5  is cooled and reduces the operating temperature of the batteries  302  within the battery pack housing  5 . 
         [0056]    Reducing the operating temperature within the battery pack housing  5  requires complicated engineering solutions; however, when the air within the battery pack housing  5  is not cooled by air sampling but instead is temperature detected with the metallic filament  111 , the batteries  302  within the battery pack housing  5  are permitted to operate passively within the thermal operating temperature band because the climate within the battery pack housing  5  is not altered by the thermal event detector  110 . 
         [0057]    Another important improvement discovered by implementing the thermal event detector  110  as the metallic filament  111  comes from the reduced complexity of air sampling methods which require the utilization of pipes, valves, springs, and levers. These additional components result in additional points of failure, which the thermal event detector  110  when implemented as the metallic filament  111  simply does not require. 
         [0058]    Yet another important improvement discovered when implementing the thermal event detector  110  as the metallic filament  111  is the ability to quickly implement the thermal event detector  110  with any existing battery  302 . It is contemplated that the thermal event detector  110  as shown and described with regard to  FIG. 3  can be implemented with the designs and components of the other embodiments without departing from the disclosure and those of ordinary skill in the art would recognize that the arrangement of components such as the thermal sensor  114 , the valve  112 , the control unit  116 , the conduits  108 , along with others could be implemented with the thermal event detector  110  as shown in  FIG. 3 . 
         [0059]    In an example of a typical application of an exemplary embodiment, a hybrid vehicle containing a high voltage battery is involved in an automobile accident causing one or more of the battery cells contained within the high voltage battery pack  1  to be damaged resulting in the interior of the housing of the battery pack  5  being compromised. In one contemplated scenario, the battery pack  1  catches on fire due to battery chemical fluids leaking out and coming into contact with exposed electricity from the automobile due to accident damage. Upon such thermal event occurring, the thermal event detector  110  in the form of a metallic filament  111  or other thermal sensor  114 , triggers the valve or flow control device for embodiments using a control unit  116  to open resulting in the flow of the fire extinguishing media  104  from the fire extinguishing case  102  through the conduits  108  allowing the nozzles  106  to spray the fire extinguishing media  104  into the housing of the battery pack  5  quenching or otherwise suppressing the fire. 
         [0060]    Referring now to  FIG. 5 , therein is shown a fifth embodiment in an isometric view. The thermal event suppression system further including an attachment support to attach the fire extinguishing media case on one side of the housing of the battery pack  5 . An exploded view of the nozzle  106  and an embodiment of the thermal event detector as a metallic filament  111  coupled to the conduits  108  which is fluidly connects the fire extinguishing media case  102  to said nozzle  106  wherein said nozzle  106  is adapted to be enclosed within a housing of the battery pack  1 . 
         [0061]    Thus, it has been discovered that the thermal suppression system furnishes important and heretofore unknown and unavailable solutions, capabilities, and functional aspects. The resulting configurations are straightforward, cost-effective, uncomplicated, highly versatile, accurate, sensitive, and effective, and can be implemented by adapting known components for ready, efficient, and economical manufacturing, application, and utilization. 
         [0062]    While the thermal suppression system has been described in conjunction with a specific best mode, it is to be understood that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the preceding description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations, which fall within the scope of the included claims. All matters set forth herein or shown in the accompanying drawings are to be interpreted in an illustrative and non-limiting sense.