# US 2022/0045385 A1 · Battery pack design and method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2022/0045385 A1 - Document ID: US20220045385A1 - Status: Published application - Kind: A1 - Application number: 17/452,068 - Filed: 2021-10-25 - Published: 2022-02-10 - Earliest claimed: 2019-04-25 - Assignees: HAPSMobile Inc. - Applicants: HAPSMobile Inc. - Inventors: Peter DELIOUSSINE; Brian JENSEN - Web page: https://patentgrep.com/patent/US20220045385A1 ## CPC - H01M 10/625: Vehicles - H01M 10/6552: Closed pipes transferring heat by thermal conductivity or phase transition, e.g. heat pipes - H01M 10/658: by thermal insulation or shielding - H01M 50/204: Racks, modules or packs for multiple batteries or multiple cells - H01M 50/249: specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64) - H01M 50/308: Detachable arrangements, e.g. detachable vent plugs or plug systems - H01M 50/3425: {in the form of rupturable membranes or weakened parts, e.g. pierced with the aid of a sharp member} - H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane - Y02E 60/10: Energy storage using batteries - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract In at least one embodiment, provided is a battery pack for a vehicle including a thin firebox for enclosing batteries and containing thermal runaway gases, thermal insulation surrounding the firebox, and a vent hole extending through the firebox and the thermal insulation to an exterior of the vehicle with vent hole plug and a pressure relief frangible vent cover at least partially covering the vent hole plug to retain it within the vent hole. ## Claims ### Claim 1 A battery pack for a vehicle, the battery pack comprising: a) a thin firebox for enclosing batteries and containing thermal runaway gases; b) thermal insulation surrounding the firebox; c) a vent hole extending through the firebox and the thermal insulation to an exterior of the vehicle; d) a vent hole plug; and e) a pressure relief frangible vent cover at least partially covering the vent hole plug to retain it within the vent hole. ### Claim 2 (depends on 1) The battery pack of claim 1, wherein the pressure relief frangible vent cover is adapted to at least partially cover the vent hole plug until the thermal runaway gases force the vent hole plug from the vent hole. ### Claim 3 (depends on 1) The battery pack of claim 1, wherein the pressure relief frangible vent cover comprises: a) a frangible flexure comprising a vent plug cover portion and a weakened region; and b) a pad portion surrounding the frangible flexure, the pad portion being separated from the vent plug cover portion by a gap between the vent plug cover portion and the pad portion, the pad portion being connected to the frangible flexure by the weakened region. ### Claim 4 (depends on 3) The battery pack of claim 3, wherein the weakened region comprises a score line. ### Claim 5 (depends on 3) The battery pack of claim 3, wherein the weakened region comprises a groove. ### Claim 6 (depends on 5) The battery pack of claim 5, wherein the weakened region comprises a “V” profile groove. ### Claim 7 (depends on 3) The battery pack of claim 3, wherein the weakened region comprises perforations. ### Claim 8 (depends on 3) The battery pack of claim 3, wherein the weakened region comprises a thinner material than an adjacent portion of the pad portion. ### Claim 9 (depends on 6) The battery pack of claim 6, wherein the weakened region comprises a more brittle material than an adjacent portion of the pad portion. ### Claim 10 (depends on 1) The battery pack of claim 1, wherein the thermal insulation comprises at least one of: a) an aerogel; orb) a vacuum panel insulation. ### Claim 11 A battery pack thermal runaway vent cover structure comprising: a) a frangible flexure comprising a vent plug cover portion and a weakened region; and b) a pad portion surrounding the frangible flexure, the pad portion being separated from the vent plug cover portion by a gap between the vent plug cover portion and the pad portion, the pad portion being connected to the frangible flexure by the weakened region. ### Claim 12 (depends on 11) The battery pack thermal runaway vent cover structure of claim 11, wherein the weakened region comprises a score line. ### Claim 13 (depends on 11) The battery pack thermal runaway vent cover structure of claim 11, wherein the weakened region comprises a groove. ### Claim 14 (depends on 13) The battery pack thermal runaway vent cover structure of claim 13, wherein the weakened region comprises a “V” groove. ### Claim 15 (depends on 11) The battery pack thermal runaway vent cover structure of claim 11, wherein the weakened region comprises perforations. ### Claim 16 (depends on 11) The battery pack thermal runaway vent cover structure of claim 11, wherein the weakened region comprises a thinner material than an adjacent portion of the pad portion. ### Claim 17 (depends on 14) The battery pack thermal runaway vent cover structure of claim 14, wherein the weakened region comprises a more brittle material than an adjacent portion of the pad portion. ### Claim 18 A method for fabricating a battery pack thermal runaway vent cover structure, the method comprising: a) forming a vent hole cover partially separated from a mounting portion; and b) forming a weakened region between the vent hole cover and the mounting portion. ### Claim 19 (depends on 18) The method of claim 18, wherein forming the weakened region comprises scoring a region of the battery pack thermal runaway vent cover structure between the vent hole cover and the mounting portion. ### Claim 20 (depends on 18) The method of claim 18, wherein forming the weakened region comprises cutting a groove between the vent hole cover and the mounting portion sufficient to allow the vent hole cover to break during a thermal runaway.