CROSS REFERENCE TO RELATED APPLICATION

[0001] This disclosure is based on and claims the benefit of an India Provisional Application No. 202211058388, entitled “Battery Safety Valve with Enhanced Features for Assembly and Compliance,” filed on 12 October 2022, which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

[0002] This disclosure relates generally to valves, and, more particularly, to safety valves for discharging gas and exhaust from a battery casing.

BACKGROUND

[0003] Certain batteries, particularly those utilized in demanding applications such as motor vehicles or electric vehicles, can experience sudden failures, such as an explosion. These batteries are typically contained in a battery casing that is sealed against an external environment so as to protect the battery cells from contamination. In the event of an explosion or thermal runaway, gas and exhaust produced by the explosion need to be released to the exterior of the battery casing. To this end, a battery safety valve may be employed, which serves to allow substances to escape out of the interior of the batter casing under certain conditions while ensuring tight sealing against ingress from the outside.

SUMMARY OF PARTICULAR EMBODIMENTS

[0004] This disclosure presents a battery safety valve having various components that independently or in combination enhance sealing of the battery casing against the environment. In particular, a seal located between the battery safety valve and the battery casing may be protected from high-pressure spray that may occur, for example, during vehicle maintenance. The battery safety valve according to this disclosure moreover provides several other features to assist in manufacturing both for production of the battery safety valve per se and for customer assembly process to the battery casing. Other benefits may include but are not limited to low production cost, enhanced system robustness, small apparatus footprint, and so forth.

[0005] In one embodiment, a battery safety valve for use with a battery casing is provided. The battery safety valve comprises a housing having a housing wall extending upwards from a bottom of the housing, a valve assembly contained within the housing and configured to control fluid communication from the battery casing through the battery safety valve, a seal positioned between the bottom of the housing and the battery casing, and a top cap configured to cover the housing. The top cap comprises an outer cap wall extending downwards from a top of the top cap, and an inner cap wall extending downwards from the top of the top cap and located radially inwards relative to the outer cap wall. In particular, the housing wall of the housing is positioned between the inner cap wall and the outer cap wall of the top cap. Moreover, an axial length of the outer cap wall covers the seal so as to shield the seal from an external environment.

[0006] In particular embodiments, the housing wall of the housing comprises one or more protrusions extending outwards and away from an exterior of the housing. In particular embodiments, the outer cap wall of the top cap comprises one or more tabs for clipping around the one or more protrusions of the housing. In particular embodiments, the one or more protrusions of the housing wall of the housing comprise one or more ribs for engaging with the one or more tabs through respective gaps of the one or more tabs.

[0007] In particular embodiments, the inner cap wall of the top cap comprises one or more ribs. In particular embodiments, the housing wall of the housing comprises one or more slots for receiving the one or more ribs of the top cap.

[0008] In particular embodiments, the outer cap wall of the top cap comprises a flange at a lower end of the outer cap wall.

[0009] In particular embodiments, the bottom of the housing is configured with a channel for receiving the seal.

[0010] In particular embodiments, the top of the top cap comprises one or more ribs. In particular embodiments, the top of the top cap comprises a tool interface.

[0011] In one embodiment, a battery valve assembly for use with a battery casing is provided. The battery valve assembly comprises a battery safety valve and a seating plate configured to engage with the battery safety valve. The battery safety valve comprises a housing having a housing wall extending upwards from a bottom of the housing, a valve assembly contained within the housing and configured to control fluid communication from the battery casing through the battery safety valve, a seal positioned between the bottom of the housing and the battery casing, and a top cap configured to cover the housing. The top cap comprises an outer cap wall extending downwards from a top of the top cap, an inner cap wall extending downwards from the top of the top cap and located radially inwards relative to the outer cap wall, and one or more first alignment features located on the top of the top cap. The seating plate comprises one or more second alignment features. In particular, the housing wall of the housing is positioned between the inner cap wall and the outer cap wall of the top cap. Moreover, an axial length of the outer cap wall covers the seal so as to shield the seal from an external environment. Furthermore, relative position of the first and second alignment features indicates orientation of the battery safety valve relative to the seating plate.

[0012] In particular embodiments, a lower end of the outer cap wall is in close proximity to the seating plate. In particular embodiments, the first alignment feature is a rib. In particular embodiments, the second alignment feature is a marking. In particular embodiments, the battery safety valve is configured to be rotated into engagement with the seating plate.

[0013] In particular embodiments, the housing wall of the housing comprises one or more protrusions extending outwards and away from an exterior of the housing. In particular embodiments, the outer cap wall of the top cap comprises one or more tabs for clipping around the one or more protrusions of the housing. In particular embodiments, the one or more protrusions of the housing wall of the housing comprise one or more ribs for engaging with the one or more tabs through respective gaps of the one or more tabs.

[0014] In particular embodiments, the inner cap wall of the top cap comprises one or more ribs. In particular embodiments, the housing wall of the housing comprises one or more slots for receiving the one or more ribs of the top cap.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Embodiments in accordance with this disclosure will now be described by reference to the accompanying drawings, in which:

[0016] FIG. 1 illustrates an example battery casing and battery safety valve, according to one or more aspects of the present disclosure; [0017] FIG. 2 illustrates an example seating plate, according to one or more aspects of the present disclosure;

[0018] FIG. 3 is a perspective view of the battery safety valve of FIG. 1 coupled to the seating plate of FIG. 2;

[0019] FIG. 4 illustrates the battery safety valve of FIG.1 from another perspective, with portions cut away for better view;

[0020] FIGs. 5A-5B respectively illustrate the battery safety valve of FIG. 1 in a closed position and an open position;

[0021] FIG. 6 illustrates a bottom view of the battery safety valve of FIG. 1 ;

[0022] FIG. 7 illustrates in cross-section the battery safety valve of FIG. 1 coupled to the seating plate of FIG. 2;

[0023] FIGs. 8A and 8B illustrate a process of coupling the battery safety valve of FIG. 1 to the seating plate of FIG. 2;

[0024] FIG. 9 illustrates another embodiment of the battery safety valve, according to one or more aspects of the present disclosure; and

[0025] FIGs. 10-11 illustrate a process of coupling the battery safety valve to the seating plate with the aid of alignment features, according to one or more aspects of the present disclosure.

DESCRIPTION OF EXAMPLE EMBODIMENTS

[0026] Illustrative embodiments of the present invention are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions may be made to achieve the specific implementation goals, which may vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.

[0027] Throughout this disclosure, a reference numeral followed by an alphabetical character refers to a specific instance of an element and the reference numeral alone refers to the element generically or collectively. Thus, as an example (not shown in the drawings), widget "la" refers to an instance of a widget class, which may be referred to collectively as widgets " 1 " and any one of which may be referred to generically as a widget "1". In the figures and the description, like numerals are intended to represent like elements.

[0028] The terms “couple” or “couples,” as used herein, are intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect electrical connection or a shaft coupling via other devices and connections.

[0029] To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the disclosure. Embodiments described below with respect to one implementation are not intended to be limiting.

[0030] The present disclosure provides for systems and methods for utilizing a battery safety valve to discharge gas and exhaust from a battery casing in the event of an explosion. While this disclosure describes the battery safety valve mainly in the context of vehicles, the battery safety valve may also be used for a DC/DC converter housing, or other electrical housing which may experience pressure increase and need a venting/pressure reduction device. The disclosed systems and methods may, in certain embodiments, reduce the sudden pressure increase due to an explosion from a sealed battery casing. The battery safety valve may be biased to seal the battery casing and may be actuated to open and allow fluid flow out of the battery casing as the pressure within the battery casing increases. While allowing exhaust to exit the battery casing through the battery safety valve, fluid or other contaminants are prevented from entering the battery safety valve to the interior of the battery casing from the outside. For example, this may be ensured by means of the labyrinth-like internal structures of the battery safety valve. Moreover, the battery safety valve according to this disclosure may provide the added benefit of shielding a seal located between the battery safety valve and the battery casing against the external environment (e.g., by an extended outer wall of the valve cap), reducing the chances of fluid leakage and seal failure, and prolonging the service life of the system. This may be especially beneficial in vehicles as the battery safety valve may be exposed to a high volume of dust or liquid, e.g., during vehicle maintenance such as car wash where a high-pressure waterjet may impinge onto the battery safety valve. Furthermore, thanks to the improved structural design of the battery safety valve according to this disclosure, manufacturing process can be simplified. For example, since the battery safety valve in some embodiments may be made 180 degrees symmetrical, simple injection molding is made feasible. Other benefits provided by the battery safety valve according to this disclosure include but are not limited to simple assembly of the battery safety valve, enhanced force and torque transmission, easy mounting (for example, by means of alignment features or other visual indicators), just to name a few.

[0031] FIG. 1 illustrates an example battery casing 100 and a battery safety valve 102 that may employ the principles of the present disclosure, according to one or more embodiments. The battery casing 100 may be any suitable size, height, shape, and any combinations thereof. Further, the battery casing 100 may comprise any suitable materials, such as metals, nonmetals, polymers, composites, and any combinations thereof. The battery casing 100 may be operable to contain one or more batteries used to provide power to a system. In certain embodiments, the battery casing 100 may be disposed within or incorporated within an electric vehicle. During operations, the one or more batteries may experience a failure or may generate an explosion. In this example of battery failure or explosion, the battery casing 100 may be sealed and may need to vent the by-products of the explosion, such as gases and exhaust, out to an external environment via the battery safety valve 102.

[0032] As illustrated, in particular embodiments, the battery safety valve 102 may be removably coupled to the battery casing 100. For example, the battery safety valve 102 may be coupled to the battery casing 100 through any suitable means, including, but not limited to, through the usage of fasteners, adhesives, interlocking components, interference fit, and any combination thereof. As shown, in particular embodiments, there may be a seating plate 104 secured to the battery casing 100 operable to couple to and receive the battery safety valve 102. The seating plate 104 may be incorporated into, coupled to, or disposed on the battery casing 100. The seating plate 104 may be configured to removably couple the battery safety valve 102 to the battery casing 100, for example, along an axis 106. An example of the battery safety valve 102 configuration and its components are described in more detail below, e.g., in FIG. 3. While a single battery safety valve 102 is illustrated for use with the battery casing 100, the present disclosure is not limited by a single battery safety valve 102. In certain embodiments, there may be one or more battery safety valves 102 used with the battery casing 100.

[0033] FIG. 2 illustrates a perspective view of the seating plate 104. The seating plate 104 may be any suitable size, height, shape, and any combinations thereof. Further, the seating plate 104 may comprise any suitable materials, such as metals, nonmetals, polymers, composites, and any combinations thereof. As illustrated, the seating plate 104 may generally be in the shape of a circle. In particular embodiments, the seating plate 104 may comprise a first inner diameter 200, a second inner diameter 202, and an outer diameter 204. Each of the first inner diameter 200, second inner diameter 202, and outer diameter 204 may be any suitable value. For example, the first inner diameter 200 may be about 28 millimeters, the second inner diameter 202 may be about 32 millimeters, and the outer diameter 204 may be about 55 millimeters. In particular embodiments, the first inner diameter 200 may be less than the second inner diameter 202. Both of the first inner diameter 200 and the second inner diameter 202 may be divided in two portions, wherein each portion is disposed across from each other. For example, a first portion 200a of the first inner diameter 200 may mirror a second portion 200b of the first inner diameter 200 and be disposed across from the second portion 200b. Likewise, a first portion 202a of second inner diameter 202 may mirror a second portion 202b of the second inner diameter 202 and be disposed across from the second portion 202b. Moreover, each of the portions 200a, 200b of the first inner diameter 200 may be disposed adjacent to the portions 202a, 202b of the second inner diameter 202. The variance between the first inner diameter 200 and the second inner diameter 202 may produce an interlocking feature to be used to couple the battery safety valve 102 to the battery casing 100. Although this disclosure describes a seating plate with a particular interlocking feature in a particular manner, this disclosure contemplates seating plates with any interlocking features in any suitable manner.

[0034] FIG. 3 illustrates a perspective view of the battery safety valve 102 coupled to the seating plate 104. The battery safety valve 102 may be manufactured through injection molding or through any other suitable methods as familiar to those skilled in the art. In particular embodiments, the battery safety valve 103 may comprise a top cap 300 and a housing 302, wherein the top cap 300 is configured to be disposed on top of the housing 302 and substantially cover the housing 302. A base 304 of the housing 302 may be inserted through the seating plate 104, wherein at least one ramp 306 disposed on the exterior of the base 304 may engage with the first inner diameter 200 (referring to FIG. 2) and with the second inner diameter 202 (referring to FIG. 2). Engagement of the at least one ramp 306 may secure the housing 302 to the seating plate 104. For example, the at least one ramp 306 may be an angled protrusion along the exterior side of the base 304. The at least on ramp 306 may comprise any suitable angle. The circumference of the base 304 may comprise the same, or smaller, dimension as the first inner diameter 200, and the second inner diameter 202 may accommodate the additional distance of the at least one ramp 306. In this example, a user may insert the base 304 through the seating plate 104 (e.g., along the axis 106 of FIG. 1) by aligning the base concentrically with the first inner diameter 200 and by aligning the at least one ramp 306 with the second inner diameter 202. Once partially inserted so that the housing 302 abuts the seating plate 104, the housing 302 may be rotated about the axis 106 so that the at least one ramp 306 is at least partially disposed underneath the first inner diameter 200. While described in this particular manner, any suitable cam-locking arrangement between the housing 302 and the seating plate 104 may be used with the battery safety valve 102. Further, in particular embodiments, the top cap 300 may comprise alignment features to visually convey to a user how to align the top cap 300 to the housing 302 for coupling and may act as a dead-stop to protect components from torque during installation. This will be more fully explained below (e.g., by referencing to FIGs. 8A-8B).

[0035] As illustrated, securing the housing 302 to the seating plate 104 may also secure the top cap 300 with respect to the seating plate 104 as the top cap 300 is coupled to the housing 302. In particular embodiments, the housing 302 may comprise one or more protrusions 308 extending outwards and away from an exterior of the housing 302. The one or more protrusions 308 may be disposed about any suitable location along the housing 302. For example, each protrusion 308 may be uniformly spaced with respect to each other along a radial direction. In particular embodiments, each protrusion 308 may comprise an upper angled surface 310 and a lower angled surface 312. The upper angled surface 310 may be a top surface of the protrusion 308 sloped upwards. The lower angled surface 312 may be a bottom surface of the protrusion 308 sloped downwards. As an example, the slopes of the upper and lower angled surfaces 310, 312 may be equivalent or different. The length of the upper angled surface 310 may be same or different from the length of the lower angled surface 312 (i.e., the upper angled surface 310 may be longer).

[0036] In particular embodiments, the top cap 300 may comprise, along its radial direction, a set of tabs 314a and 314b to be associated with each of the one or more protrusions 308. The set of tabs 314a, 314b may be any suitable size, height, shape, and any combinations thereof. As an example and not by way of limitation, when coupling the top cap 300 to the housing 302, each set of tabs 314a, 314b may be locked about each protrusion 308, e.g., by pressing over the upper angled surface 310 and coming to rest underneath the lower angled surface 312. In doing so, the upper and lower angled surface 310, 312 of the protrusion 308 may prevent the set of tabs 314a, 314b from translating up and down such that the top cap 300 is relatively fixed over the housing 302. Although this disclosure describes a top cap and a housing with a particular coupling feature in a particular manner, this disclosure contemplates top caps and housings with any suitable coupling features in any suitable manner. In certain embodiments, the top caps and the housings may additionally or alternatively include interference fits, snap fits, clippers, retainers, or other suitable connectors for coupling the top cap and the housing together. As an example, in certain embodiments, the set of tabs may be connected together to form a unitary piece to catch below the protrusion. As another example, while shown as having four protrusions and four sets of tabs, in certain embodiments, the top cap and the housing may include less, more, or no protrusions or tabs, respectively.

[0037] In particular embodiments, the top cap 300 may further comprise one or more windows 316 defined through its radial wall. Each of the one or more windows 316 may be any suitable size, height, shape, and any combinations thereof. While illustrated as generally rectangular in shape, each window 316 may be any other shape or size. The windows 316 may be disposed about any suitable location along the circumference of the top cap 300. In particular embodiments, the one or more windows 316 may be configured to provide fluid communication between the housing 302 and an external environment. In particular embodiments, the sets of tabs 314a, 314b may also function to provide fluid communication.

[0038] FIG. 4 illustrates another embodiment of a top cap 400 and a housing 402 of the battery safety valve 103 according to this disclosure, with portions of the top cap 400 and the housing 402 partially cut away for better observation. In particular embodiments, the top cap 400 and the housing 402 may substantially be similar to the top cap 300 and the housing 302 described at length above in that the top cap 400 may include, along its radial direction, sets of tabs 414a and 414b, and the housing 402 may include one or more protrusions 408 to be fitted with the set of tabs 414a and 414b. In the illustrated embodiment, in addition to an upper angled surface 410 and a lower angled surface 412, the protrusion 408 may also include a rib 424 extending from the upper angled surface 410, past the lower angled surface 412, and further vertically downwards to a certain distance. As an example and not by way of limitation, the rib 424 may have a lateral length extending outwards and away from an exterior of the housing 302 such that when the top cap 400 is clipped onto the housing 402, the set of tabs 414a, 414b stay short of or flush with the rib 424 radially. As another example and not by way of limitation, the rib 424 may have a vertical length extending downwards to such an extent that when the top cap 400 is clipped onto the housing 402, the rib 424 fits into a gap formed between the set of tabs 414a, 414b. Configured this way, by inserting the rib 424 in between the set of tabs 414a, 414b, as the top cap 400 rotates (e.g., during assembly for rotationally coupling the battery safety valve 103 to the seating plate 104), rotational force may be transferred via the rib 424 into the set of tabs 414a, 414b of the housing 402 such that the housing 402 rotates together with the top cap 400. In other words, relative rotation between the top cap 400 and the housing 402 may be prevented, for example, as the battery safety valve 103 is screwed to the seating plate 104. Moreover, coupling of the top cap 400 to the housing 402, for example, by means of clipping, is not affected by the rib 424.

[0039] In particular embodiments, in addition or alternative to the rib 424 of the housing 402, the top cap 400 may also be provided with one or more internal ribs 416. This can be more clearly observed in the cut-away area of FIG. 4 since the internal rib 416 is hidden from the outside. As an example and not by way of limitation, the internal rib 416 may be disposed within the top cap 400 and extend vertically downwards from an upper surface 418 of the top cap 400. As another example and not by way of limitation, the internal rib 416 may be formed on an internal structure (e.g., an inner cap wall) of the top cap 400 and protrudes radially outwards. Correspondingly, in particular embodiments, a housing wall 422 of the housing 402 may be provided with one or more slots or cut-outs 420 for receiving the internal rib 416. In this way, the configuration of the internal rib 416 and the cut-out 420 may allow axial movement of the top cap 400 relative to the housing 402 when the top cap 400 is fitted over the housing 402, while preventing rotation of the top cap 400 with respect to the housing 402.

[0040] While the illustrated embodiment of FIG. 4 shows the housing as having four protrusions (with two of the protrusions including ribs and the other two devoid of ribs) and the top cap as having two internal ribs, it should be appreciated that this disclosure contemplates any suitable number, configuration, and combination of the protrusion, the ribs, and the internal ribs. As an example, in certain embodiments, each of the protrusions may include a rib. As another example, in certain embodiments, none of the protrusions includes a rib. As a further example, in certain embodiments, the top cap may include less, more, or no internal ribs.

[0041] FIGs. 5A-5B illustrate the battery safety valve 102 operating between a closed position and an open position. As illustrated, the battery safety valve 102 may be securely coupled to the seating plate 104 in order to operate. A seal 500, such as an O-ring, may be disposed between the housing 302 and the seating plate 104, wherein the seal 500 may be configured to create a seal between the housing 302 and seating plate 104 as the housing 302 coupled to the seating plate 104. In other embodiments, the seal 500 may be an x-ring, slim washer, d-ring, face-seal, flat-seal, or the like. The seal 500 may be partially stretched or elastically deformed when placed around housing 302. In particular embodiments, fluid may be directed to flow from an interior of a battery casing 100 (referring to FIG. 1) to and through the housing 302 due to the seal 500. In particular embodiments, to shield the seal 500 from external elements, the top cap 300 may be disposed over and around housing 302 to abut or rest against the seating plate 104. As illustrated, the top cap 300 may be disposed to rest against seating plate 104 at a distance laterally greater than the location of the seal 500 between housing 302 and seating plate 104. Configured as such, the top cap 300 may form a protection around the seal 500 to prevent access to seal 500, for example, by liquid ejecting from the outside onto the battery safety valve 102, e.g., during car wash.

[0042] In particular embodiments, the extended top cap 300 may help reduce angle misalignment with respect to securing the base 304 to the seating plate 104 such that the battery safety valve 102 may be easily aligned with the seating plate 104 during assembly. For example, manual operation may have previously applied excess force on one side of the top cap 300, resulting in compression of the seal 500 on that side but lifting up the top cap 300 on an opposing side. In particular embodiments, the top cap 300 may additionally function as a dead-stop so as to prevent overrotation of the battery safety valve 102 relative to the seating plate 104 during torque installation. As an example, when rotated into a lock position, at least a portion of the top cap 300 (e.g., an outer wall thereof, which will be discussed in detail below) may come into close contact with the seating plate 104, thereby preventing any further rotation downwards.

[0043] In one or more embodiments, the placement of the top cap 300 around the seal 500 may align with improved performance in view of an IP69K standard, which indicates resistance against dust or water ingression under high-pressure or high-temperature conditions. Specifically, the IP rating system is an internationally recognized scale, published by the International Electrotechnical Commission (IEC), to provide decision-makers with detailed information about how their products can hold up against environmental factors that may occur in industrial plants. By defining a specific rank, rather than using vague terms such as “waterproof,” the IP system ensures specific degrees and expectations when products are faced with solid objects of certain sizes and liquids of varying temperatures and pressures. IP ratings contain two numbers; the first refers to the amount of protection against solid particles and the second refers to protection against liquids. The first number, which can be assigned as 0-6, ranges from no protection against any object to dust-tight and complete protection against contact. Devices with lower numbers are effective against large surfaces and parts of the body, while those with higher numbers can protect against tools, wires, and dust. The 6 rating indicates a dust-tight enclosure. The second number of the IP rating, which categorizes a product’s protection against harmful entrance of water, ranges from 0-9k. Products with lower numbers offer protection against dripping water, while those with higher numbers are effective against spraying water, water jets, and immersion. The 9k rating signifies that a device is protected against close-range, high-pressure, and high-temperature spray downs. Products with higher IP ratings are better suited to stand up against harsh environments and factors, and the IP69K rating ensures the highest degree of protection against objects/ dust and liquid intruding into the enclosures of devices and equipment.

[0044] In particular embodiments, the battery safety valve 102 may include a valve assembly that is contained within the housing 302 and configured to control fluid communication from the battery casing 100 through the battery safety valve 102. While the following describes the valve assembly using a piston device, it should be understood that this disclosure is not limited to such embodiments. Other suitable types of valves may be employed (such as a ball valve, a butterfly valve, etc.) without departing from the scope of this disclosure.

[0045] In the closed position as better seen in FIG. 5A, a spring 502 is disposed between the top cap 300 and the housing 302, which may be configured to bias a piston head element 504 against an internal shoulder 506 of the housing 302. The spring 502 may be disposed underneath the top cap 300 and on top of the piston head element 504. In certain embodiments, the spring 502 may be in a default expanded state pushing the piston head element 504 down against the internal shoulder 506. In other embodiments, the spring 502 may not be experiencing a force and may be in a restful state that does not force the piston head element 504 against the internal shoulder 406. But in these embodiments, for example, the piston head element 504 may remain disposed against the internal shoulder 506 due to gravity. The internal shoulder 506 may partially extend inwards from a central bore 508 of the housing 302 and may be configured to receive the piston head element 504. In particular embodiments, the central bore 508 may allow fluid communication through the housing 302 (e.g., from within the battery casing 100). [0046] In particular embodiments, while in the closed position, there may be no fluid communication between the battery casing 100 and an external environment through the battery safety valve 102. In other words, the battery safety valve 102 seals off the battery casing 100 against the external environment. Fluid may exit the battery casing 100 when there is a sufficient increase in pressure to actuate the spring 502 to compress and allow fluid to discharge through the battery safety valve 102. However, fluid may not enter the battery safety valve 102 from the external environment, e.g., due to the seal 500, the labyrinth-like wall structures between the top cap 300 and the housing 302, and so forth, which will be discussed further below. In particular embodiments, when in the closed position, the piston head element 504 may be seated against the internal shoulder 506. As illustrated, the piston head element 504 may include a rubber element 510 incorporated therein and operable to seal against the internal shoulder 506. The rubber element 510 may be any suitable size, height, shape, and any combination thereof. The rubber element 510 may be incorporated into the piston head element 504 through any suitable methods, such as by over-molding or the like. The rubber element 510 may comprise any suitable rubber material and/or polymer composition. In particular embodiments, the rubber element 510 may be configured to seal the central bore 508 and prevent fluid communication therethrough. In other embodiments, the piston head element 504 may be utilized without the rubber element 510. In these embodiments, the piston head element 504 may seal the central bore 508 by other suitable means. The piston head element 504 may comprise any suitable materials, such as metals, nonmetals, polymers, composites, and any combinations thereof.

[0047] In the embodiment as depicted, the rubber element 510 may be disposed through a center plate of the piston head element 504 and form a circular pad covering at least a substantial portion of the underside of the piston head element 504. For example, the center plate may be provided with one or more holes or grooves such that during assembly rubber material may be filled through the holes and over-molded onto the center plate (e.g., to its bottom) so as to form the rubber element 510. Moreover, the rubber element 510 may include an annular protrusion extending downwards from the circular pad so as to seal on top of the internal shoulder 506. Although this disclosure describes a housing with a particular piston head element in a particular manner, this disclosure contemplates housings with any suitable piston head elements in any suitable manner. [0048] Further, in particular embodiments, fluid coming from the external environment may not be allowed to run through the battery safety valve 102 to encounter the piston head element 504. To this end, for example, the housing 302 may comprise a housing wall 512 extending upwards from a bottom 520 of the housing 302. In particular embodiments, the housing wall 512 may also be configured to transfer force from the top cap 300 to the housing 302. As an example and not by way of limitation, force transfer may occur through the protrusions 308 (referring to FIG. 3) and the sets of tabs 314a, 314b (referring to FIG. 3), through the ribs 424 (referring to FIG. 4) and the sets of tabs 414a, 414b (referring to FIG. 4), or through the internal ribs 416 (referring to FIG. 4) and the cut-outs 420 (referring to FIG. 4). In particular embodiments, the housing wall 512 may be positioned between an outer cap wall 514 and an inner cap wall 516 extending downward from the top cap 300 as the top cap 300 is coupled to the housing 302. As an example and not by way of limitation, the outer cap wall 514 may include one or more windows 316 (referring to FIG. 3) for fluid passage. As another example and not by way of limitation, the outer cap wall 514 may include one or more sets of tabs 314a, 314b (referring to FIG. 3) configured to clip around one or more protrusions 308 disposed along the housing wall 512 of the housing 302. As a further example and not by way of limitation, the inner cap wall 516 may include one or more internal ribs 416 (referring to FIG. 4) configured to engage with one or more cut-outs 420 formed through the housing wall 512 of the housing 302. In particular embodiments, the positions and configurations of the inner cap wall 516, the housing wall 512, and the outer cap wall 514 may be designed to minimize ingress into the battery safety valve 102. For example, the outer cap wall 514 may extend downwards from the top of the top cap 302 to such a length along the axial direction that it substantially covers the seal 500 radially. As another example, when coupled to the seating plate 104, a lower end of the outer cap wall 514 may be positioned in close proximity or in contact with the seating plate 104 in order to shield the seal 500 from the external environment such as high-pressure fluid spray. Moreover, while fluid may flow from the external environment into the battery safety valve 102 through the one or more windows 316, the staggered configuration of the housing wall 512 of the housing 302 and the cap inner wall 516 of the top cap 300 may prevent further fluid flow into the battery safety valve 102.

[0049] The open position of the battery safety valve 102 according to this disclosure is better illustrated by FIG. 5B. In particular embodiments, the internal pressure within the battery casing 100 (referring to FIG. 1), which may be the result of explosion or battery failure, may push up against the piston head element 504, as indicated by the solid arrow. As the pressure acting upwards overcomes the downward biasing force of the spring 502, the piston head element 504 may translate up and open the passage of the central bore 508, thereby allowing fluid flow (i.e., such as in the form of gases and exhaust) to flow through the central bore 508 and out of the battery safety valve 102. An example fluid flow path is indicated by the dashed arrows of FIG. 5B. Specifically, the fluid flow may first encounter the inner cap wall 516 of the top cap 300. As illustrated, in particular embodiments, the inner cap wall 516 may comprise one or more internal windows 518, which may provide an opening (e.g., a gap with the bottom 520 of the housing 302 as shown) to allow fluid to flow through. Similar to the one or more windows 316, the internal windows 518 may be any suitable size, height, shape, and any combinations thereof. The fluid flow may then be directed to flow through the internal windows 518, around or over the housing wall 512, and finally out of the battery safety valve 102 through the one or more windows 316 of the outer cap wall 514. When the internal pressure in the battery casing 100 decreases, the spring 502 may return to expand and force the piston head element 404 back down to rest and seal against the internal shoulder 406 to prevent further fluid flow out of the battery casing 100.

[0050] FIG. 6 illustrates the bottom perspective view of the housing 302 of the battery safety valve 102. In particular embodiments, the bottom 520 of the housing 302 may be configured with a surface structure to retain the seal 500. As an example and not by way of limitation, the bottom 520 may be slotted or provided with a recess, a groove, a channel, a protrusion, a ridge, or the like for holding the seal 500 in place. In the illustrated embodiment, three nobs 602 are arranged on each side of the bottom 520 for pressing against the seal 500 so as to retain the seal 500 at the proper position. While described and illustrated as such, this disclosure contemplates any forms, structures, configurations, or numbers of features for securing the seal relative to the battery safety valve.

[0051] FIG. 7 illustrates the battery safety valve 102 coupled to the seating plate 104. As illustrated, the base 304 may be partially inserted through the seating plate 104. During coupling, the at least one ramp 306 may align with the second inner diameter 202 (referring to FIG. 2), and the battery safety valve 102 may be actuated to rotate by a locking tool (as can be seen in FIGs. 8A-8B) to secure to seating plate 104. As the battery safety valve 102 couples to seating plate 104, the seal 500 may be compressed between the housing 302 and the seating plate 104. The outer cap wall 514 (referring to FIGs. 5A-5B) of the top cap 300 may extend over and substantially cover the housing 302 (e.g., along a vertical direction) to rest against the seating plate 104 during coupling. The vertical extension of the top cap 300 may function to protect the seal 500 from the external environment (such as a high-pressure waterjet), as the seal 500 is disposed in an interior space defined by the housing 302, the top cap 300, and the seating plate 104.

[0052] FIGs. 8A-8B illustrate a process of coupling the battery safety valve 102 to the seating plate 104, in which FIG. 8A illustrates an exploded view of a locking tool 800, the battery safety valve 102, and the seating plate 104, and FIG. 8B illustrates the locking tool 800 coupled to the battery safety valve 102 to secure the battery safety valve 102 to the seating plate 104. In particular embodiments, the top cap 300 may be structured with a tool interface, which is located on the top of the top cap 300. By providing the tool interface at the top cap 300, shorter installation tool (e.g., the locking tool 800) may be used. This may save material, reduce component weight, offer better ergonomics, and lower overall assembly costs.

[0053] As shown in the example, there may be a recessed channel 802 disposed at the top of the top cap 300 and configured to receive the locking tool 800. The recessed channel 802 may be any suitable size, height, and/or shape. As an example and not by way of limitation, the recessed channel 802 may generally be in the shape of a polygon. In particular embodiments, the recessed channel 802 may comprise a set of ribs 804 dividing the recessed channel 802 into halves. The ribs 804 may facilitate force or torque transmission when the battery safety valve 102 is rotated onto the seating plate 104. For example, the set of ribs 804 may be configured to be received by the locking tool 800. As the set of ribs 804 are disposed at a set location along the recessed channel 802, the locking tool 800 may be limited in its configuration with coupling to the top cap 300. In other embodiments, a user may manually actuate the top cap 300 to rotate via the recessed channel 802 and the set of ribs 804 without using the locking tool 800.

[0054] In particular embodiments, the locking tool 800 may comprise an alignment feature 806 and a receptacle 808. The receptacle 808 may be configured to receive any suitable tool to actuate the locking tool 800 to rotate. The alignment feature 806 may be a marking disposed on the locking tool 800 configured to convey how the locking tool 800 is positioned with respect to the top cap 300. The alignment feature 806 may comprise any suitable size and/or shape. For example, the locking tool 800 may be disposed on top of the top cap 300 in order to couple the battery safety valve 102 to the seating plate 104. Because the top cap 300 comprises the set of ribs 804, the locking tool 800 may require alignment prior to being seated on the top cap 300. For example, to align the locking tool 800 to the top cap 300, a user may line up the alignment feature 806 with the set of ribs 804. Configured as such, the tool assembly may provide for a reduction in height and diameter of the locking tool 800, thereby providing for less material cost and less weight. It should be understood that the locking tool as disclosed herein is provided for the purpose of explaining the assembly process only and should not be read as limiting the scope of this disclosure.

[0055] In particular embodiments, the seating plate 104 may further comprise a secondary alignment feature 810. As an example and not by way of limitation, the secondary alignment feature 810 may be a marking (for example, such as a dot, a line, or the like) configured to convey when the battery safety valve 102 is in a locked position. Similar to the alignment feature 806, the secondary alignment feature 810 may comprise any suitable size and/or shape. During assembly, a user may insert the battery safety valve 102 partially through the seating plate 104 with the locking tool 800 attached at the top. In a first position, as illustrated in FIG. 8B, the battery safety valve 102 may be unlocked with respect to the seating plate 104, wherein the battery safety valve 102 can be removed. In this first position, the alignment feature 806 may be perpendicular to the secondary alignment feature 810. To transition to the locked position, a user may rotate the locking tool 800 and the battery safety valve 102 until the alignment feature 806 (and consequently the rib 804 underneath) is laterally aligned with the secondary alignment feature 810. The user may rotate either in a clockwise or counterclockwise direction as long as the alignment features 806, 810 line up. In particular embodiments, the top cap 300 may comprise an illustration to be conveyed to a user corresponding to which direction to rotate the battery safety valve 102 in order to lock and unlock from the seating plate 104. Although this disclosure describes the battery safety valve and the seating plate as having two particular alignment ribs and two particular markings, respectively, in a particular manner, this disclosure contemplates battery safety valves and seating plates with any suitable alignment ribs and any suitable markings in any suitable manner. As an example, the battery safety valve and the seating plate may have less, more, or no alignment rib or marking, respectively.

[0056] FIG. 9 illustrates, in cross-section, another embodiment of the housing 302 of the battery safety valve 102 according to this disclosure. In this embodiment, the piston head element 904 may be similar to the piston head element 504 described at length above with reference to FIGs. 5A-5B in that it may include a rubber element 910 incorporated therein and operable to seal against the internal shoulder 506. The rubber element 910 may be any suitable size, height, shape, and any combination thereof. The rubber element 910 may be incorporated into the piston head element 504 through any suitable methods, such as by over-molding or the like. The rubber element 910 may comprise any suitable rubber material and/or polymer composition. In particular embodiments, the rubber element 910 may be configured to seal the central bore 508 and prevent fluid communication therethrough. In other embodiments, the piston head element 904 may be utilized without the rubber element 910. In these embodiments, the piston head element 904 may seal the central bore 508 by other suitable means. The piston head element 904 may comprise any suitable materials, such as metals, nonmetals, polymers, composites, and any combinations thereof.

[0057] In the embodiment as depicted, the rubber element 910 may be a circular ring disposed along a circumferential direction on the underside of the piston head element 904 and configured to seal off the gap between the piston head element 904 and the internal shoulder 506. As illustrated, the rubber element 910 may be formed around the center plate 906 of the piston head element 904 so as to expose its bottom. As an example and not by way of limitation, to facilitate attachment of the rubber element 910 to the piston head element 904, a rim 908 of the piston head element 904 may be provided with one or more holes or grooves such that during assembly rubber material may be filled through the holes and over-molded on to the rim so as to form the rubber element 910. Although this disclosure describes a housing with a particular piston head element in a particular manner, this disclosure contemplates housings with any suitable piston head elements in any suitable manner.

[0058] With continued reference to FIG. 9, in particular embodiments, the outer cap wall 514 may additionally include a flange 912 near the lower end of the outer cap wall 514. As an example and not by way of limitation, the flange 912 may extend radially outwards from the wall body such that the flange 912 may have an increased outer diameter as compared to other portions of the outer cap wall 514. By providing such a structural enhancement, protection of the seal 500 against the outside is further ensured. Moreover, the flange 912 may assist in torque installation as it creates a larger base that may reduce miss angle rotation. In particular embodiments, the bottom of the housing 302 may be structured with a channel 914 for at least partially receiving the seal 500. For example, an outer wall of the channel 914 may add another layer of protection for the seal 500 against outside.

[0059] FIG. 10 schematically illustrates how the battery safety valve 102 may be coupled to the seating plate 104, and consequently to the batter casing. In particular embodiments, as already described above, the top surface of the top cap 300 may be configured with one or more alignment features 1002 such as one or more ribs 804. Alternatively, the alignment features 1002 may take form as cut-outs, protrusions, markings, or other suitable surface structures. In the embodiments where the alignment features are cut-outs, for example, they may be manufactured as part of the stamping process so that no additional manufacturing step is needed. In the embodiments where the alignment features are ribs, for example, the ribs 804 may facilitate force or torque transmission when the battery safety valve 102 is rotated onto the seating plate 104, e.g., by means of a locking tool or manually by a user. Additionally or alternatively, as another example, the ribs 804 may provide a visual indication of the rotational position of the battery safety valve 102 relative to the seating plate 104. To cooperate with the alignment features of the top cap 300, the seating plate 104 may be provided with one or more secondary alignment features 1004 (for example, such as a dot, a line, or the like) configured to convey when the battery safety valve 102 is orientated in a locked position. During assembly, a user may insert the battery safety valve 102 partially through the seating plate 104. In an initial, not assembled position, as illustrated on the left of FIG. 10, the battery safety valve 102 may be unlocked with respect to the seating plate 104, wherein the battery safety valve 102 can be removed. In this position, the alignment features 1002 may be perpendicular to the secondary alignment features 1004. To transition to the locked position, a user may rotate the battery safety valve 102, for example, in a clockwise direction past a partially assembled position to a full assembled position, where the alignment features 1002 are laterally aligned with the secondary alignment features 1004. For example, in the full assembled position, the base 304 of the housing 302 is securely engaged with the seating plate 104 via the ramp 306. [0060] Referring to FIG. 11, which similarly illustrates how the battery safety valve 102 may be coupled to the seating plate 104 and consequently to the batter casing, in particular embodiments, the top cap 300 may comprise an illustration to be conveyed to a user corresponding to which direction to rotate the battery safety valve 102 in order to lock and unlock from the seating plate 104. As an example and not by way of limitation, by turning the battery safety valve 102 with respect to the seating plate 104 from a position indicated by a lock to a position indicated by an unlocked lock following a direction shown by an arrow, the battery safety valve 102 may be unlocked and disengaged from the seating plate 104, or vice versa. Again, it will be appreciated that although this disclosure describes the battery safety valve and the seating plate as having a particular alignment feature or visual illustration, respectively, in a particular manner, this disclosure contemplates battery safety valves and seating plates with any suitable alignment features and any suitable visual illustrations in any suitable manner.

[0061] It will be appreciated by one of ordinary skill in the art that this disclosure contemplates not only the combination of features as set out in the above and depicted in the figures but also any other suitable combination of features. For example, the internal rib 416 described with reference to FIG. 4 may alternatively be disposed on the housing wall 422 of the housing 302, while the cutout 420 described with reference to FIG. 4 may alternatively be disposed on the inner cap wall 516 of the top cap 300 described with reference to FIGs. 5A-5B. In addition, the embodiments disclosed herein are only examples, and the scope of this disclosure is not limited to them. Particular embodiments may include all, some, or none of the components, elements, features, functions, or operations of the embodiments disclosed above.

[0062] Herein, “or” is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A or B” means “A, B, or both,” unless expressly indicated otherwise or indicated otherwise by context. Moreover, “and” is both joint and several, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A and B” means “A and B, jointly or severally,” unless expressly indicated otherwise or indicated otherwise by context.

[0063] The scope of this disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the example embodiments described or illustrated herein that a person having ordinary skill in the art would comprehend. The scope of this disclosure is not limited to the example embodiments described or illustrated herein. Moreover, although this disclosure describes and illustrates respective embodiments herein as including particular components, elements, feature, functions, operations, or steps, any of these embodiments may include any combination or permutation of any of the components, elements, features, functions, operations, or steps described or illustrated anywhere herein that a person having ordinary skill in the art would comprehend. Furthermore, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative. Additionally, although this disclosure describes or illustrates particular embodiments as providing particular advantages, particular embodiments may provide none, some, or all of these advantages.