Tesla's Crash Protection Methods for EV Batteries

Electric vehicle chassis integrated module system that improves battery safety by combining internal protection with external protection. The system uses sensors to monitor acceleration and temperature of the chassis body. If abnormal conditions are detected, a controller activates a fire suppressant system by opening a valve to release an extinguishing agent into the battery pack. This provides both internal and external protection against battery fires.

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Fire suppression system for improving the reliability of lithium-ion batteries in high-speed electric vehicles. The system uses a centralized control device, smoke/temperature sensor, and fire extinguisher. The sensor monitors battery environment and sends data to the control device. If conditions indicate thermal runaway, the control device activates the fire extinguisher. This prevents fires by suppressing runaway events. The system also has backup power, monitoring, and extinguisher inhibition features.

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Battery pack with enhanced fire safety to prevent spread of thermal events between cells. The pack has compartments for each cell, a water injection system, and cooling. Cells have internal sensors to detect thermal runaway. If a cell fails, water is injected into its compartment to suppress flames and gas. Surrounding cells are cooled to prevent chain reaction. This isolates failures and prevents pack-wide fire.

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Battery box design to mitigate thermal runaway and suppress fires in battery modules. The box has a temperature sensor, controller, and spraying apparatus above the module. If the box temperature exceeds a threshold, the controller activates the sprayer to shoot an extinguishing agent onto the module. This extinguishes any fire and prevents spread. The box also has a liquid cooling plate with high-temperature cracking holes. If the plate temperature exceeds a threshold, the coolant sprays the module to cool it and suppress thermal runaway.

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Safety monitoring system for power battery compartments in electric vehicles to detect internal deformation and prevent battery failure due to impact. The system has a monitoring component inside the battery compartment with sensors connected to a central control system. The monitoring component has an impact positioning system with relays and movable blocks that deform upon impact to trigger alerts. This allows early detection of compartment deformation from impacts that could damage the battery.

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Battery assembly with prevention of thermal runaway propagation between cells to reduce the risk of battery fires and explosions. The assembly uses separate heat insulation plates between cells, ventilation components above each cell, and cushioning members in the ventilation holes. When a cell experiences thermal runaway, the sensor detects the high temperature and signals the ventilation component to open, allowing heat dissipation. The insulation prevents core-to-core transmission, and the cushioning reduces damage from impacts.

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A safety system for preventing fires and explosions in battery packs of electric vehicles. The system uses sensors to detect abnormal conditions like overheating, electrolyte leakage, smoke, and odor inside the battery boxes. If sensors detect issues, a control device initiates cooling and fire suppression. Coolant pipes connect the batteries to a central cooling system. Solenoid valves and fire extinguishers are actuated to cool and extinguish any fires. This allows rapid response to battery pack issues before they escalate into catastrophic events.

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Lithium battery pack with a flame retardant mechanism to prevent explosions and fires during battery failure. The pack has a housing with protection components above a fixed plate and cooling/flame-retardant components below. If a battery bulges or fails, the housing pressure increases. The fixed plate pushes against a movable plate via a spring and adhesive. High temperature melts the adhesive, separating the plates and preventing further pressure buildup. This reduces the probability of explosion. The cooling components dissipate heat. The flame-retardant components suppress fire propagation.

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Safety monitoring device for preventing battery explosions in electric vehicle packs. The device uses a sliding guard mechanism to eject a faulty battery out of the pack when sensors detect overheating or smoke. The guard slides the battery out of the pack and opens doors to cover it. A firing pin pierces a pressure tank to release extinguishing agent around the ejected battery. This isolates the exploding battery from the pack to prevent chain reactions.

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Fire and explosion prevention device for electric batteries that can block flame leakage and discharge pressure generated during thermal runaway to prevent fires from spreading. The device consists of a ceramic vessel inside the battery pack that accommodates multiple battery cells. The ceramic vessel has pores to block flames and disperse pressure. Exhaust ports in the pack case vent internal gas pressure. Sensors detect impacts and temperatures to identify battery damage and inject insulating oil into damaged modules. A constant temperature maintenance system links to sensors to keep vessel/case temps appropriate.

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New energy vehicle battery pack anti-collision protection device that provides proactive impact mitigation for lithium battery packs in electric vehicles. The protection system uses a vented enclosure around the battery pack with a collapsible barrier that closes over the vent holes when a collision is detected. This allows normal ventilation and cooling when the vehicle is driving, but collapses to prevent debris entry and containment during impacts. The barrier is actuated by a sensing component that detects abnormal driving conditions. The enclosure also has heat sinks on the bottom to support the pack and dissipate heat. This provides active protection without covering the pack entirely and restricting cooling.

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A fire monitoring, prevention and control system for lithium battery packs in electric vehicles that can quickly detect and suppress thermal runaway events. The system uses sensors inside the battery pack to monitor temperature, gas composition, smoke, etc. It analyzes the data to detect runaway conditions and triggers actions to suppress and cool the affected cells before they escalate into a full-blown fire. The system can also predict runaway based on advanced models and take preventive measures.

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Battery box design for electric vehicles that absorbs collision energy and suppresses thermal runaway of the battery pack. The battery box has an energy-absorbing device on the front side to protect the batteries from damage during frontal impacts. This device contains a damper, like a magnetorheological damper, that converts mechanical energy from impacts into electrical energy. It only activates when a collision occurs and does not consume battery power normally. The box also has a thermal runaway device with a fire extinguisher storage chamber outside the battery compartment. A fire extinguisher flows into the battery compartment through channels to spray the batteries if they overheat. This prevents thermal runaway.

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Active safety protection device for thermal runaway of lithium-ion battery packs in electric vehicles to prevent explosions and fires. It uses an air conditioning system to quickly discharge and cool the battery pack when it enters a warning state. A refrigerant transmission pipeline connects the pack to the AC unit. A control valve allows refrigerant to flow into the pack when a sensor detects warning conditions. This rapidly discharges residual high-temperature gas and cools the pack to reduce secondary thermal runaway risks.

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Explosion-proof lithium battery for automobiles that can quickly suppress and contain internal cell failures to prevent chain reactions and explosions. The battery has multiple explosion-proof boxes, each containing a lithium cell. If a cell overheats or shorts, a controller detects the issue and activates a high-pressure water pump to spray cooling water into the affected box. If cooling fails, an external fire truck can connect to a fire connection. The dispersed box design prevents cell failures from spreading.

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Integrated fire suppression system for battery packs using existing cooling channels to deliver suppressant during thermal runaway. The system has a suppression module with a suppressant, which takes over cooling channel passages during failures. The suppressant pressure ruptures channel apertures to deliver suppressant at the failure site. This leverages existing channels for targeted suppression without extra piping. The system can also have dedicated suppressant channels with perforations for uniform suppression.

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A lithium battery and a lithium battery high temperature protection structure to prevent thermal runaway fires in lithium batteries used in electric vehicles. The protection structure includes a sealed containment shell with a rotating cover, internal flow guides, explosion valves, filters, cooling, alarm, and fire suppression systems. The containment shell surrounds the lithium battery pack and prevents explosions and fires. The cover seals the shell but can rotate open for access. The flow guides vent pressure if needed. Filters neutralize released gases. The cooling system lowers temperature. The alarm warns of danger. The fire suppression system extinguishes fires.

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Collision protection system for electric vehicle batteries to prevent damage and thermal runaway during collisions. The system uses a BMS module, collision sensors, MOSFETs, and a battery matrix control unit. When a collision is detected, the matrix control unit disconnects power to the battery pack using MOSFETs. This protects against battery rupture and thermal runaway caused by collisions. Rectangular energy absorbers between the battery box and covers prevent sharp objects from damaging the pack. The box and covers have tight interference fits to prevent shifting during collisions.

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Battery pack for electric vehicles with improved fire suppression during thermal runaway. The battery pack has a built-in fire extinguishing device inside the pack enclosure. It consists of a main body filled with fire suppressant and a sensor-equipped injection structure between the battery cells. When smoke is detected during thermal runaway, the sensor activates the injection ports to spray fire suppressant onto the cells. This quickly extinguishes the fire and prevents it from spreading. The fire suppression system is integrated into the pack to address internal fires and improve safety.

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A lithium-ion battery pack with an integrated fire suppression system to prevent thermal runaway and explosions in batteries used in electric vehicles. The battery pack has a fire response unit inside that can activate a reaction when the battery overheats. The response unit has movable components that create gaps and initiate chemical reactions to suppress fires. The movable components expand due to thermal expansion or extrusion force from overheating. This creates gaps between the components and the housing to allow fire suppression chemicals to react. The chemicals, like aluminum sulfate and sodium bicarbonate, expand and generate gas to suppress the fire. The reaction linkage frame moves the components apart when the battery overheats to allow the reaction to occur.

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