Reinforced Aerogel Heat Control Members for EV Battery Fire Barriers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional insulation materials for lithium ion battery modules are inadequate in providing effective thermal management and fire protection due to their limited thermal resistance, high temperature tolerance, and weight, which poses a risk of heat and fire propagation.
Innovation Solution
Development of reinforced aerogel compositions with improved compressibility, compressional resilience, and thermal resistance, integrated into heat control members that include layers of aerogel compositions with additives and thermally capacitive materials to minimize thermal conductivity and maintain low temperatures across multiple layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation materials (foam or fiber sheets) are used to block thermal runaway propagation, then fire protection is provided, but the thickness and weight of the insulation must be increased to achieve effective thermal management
Solution Approach 1:
The patent changes the thermal conductivity parameter by introducing aerogel materials with extremely low thermal conductivity (k < 0.03 W/m·K), which is 2-6 times lower than conventional insulation materials. This parameter change allows achieving the same fire protection with significantly reduced thickness and weight
Solution Approach 2:
The patent uses composite aerogel structures combining different aerogel materials (silica aerogel, carbon aerogel, metal oxide aerogel) with binding agents to create lightweight composite insulation layers that provide superior fire protection while minimizing weight
2Reliability
If conventional insulation materials are used to block thermal runaway propagation, then fire protection is provided, but the thickness of the insulation must be increased to achieve effective thermal management
Solution Approach 1:
The patent changes the thermal conductivity parameter by introducing aerogel materials with extremely low thermal conductivity (k < 0.03 W/m·K), which is 2-6 times lower than conventional insulation materials. This parameter change allows achieving the same fire protection with significantly reduced thickness
Solution Approach 2:
The patent transitions from thick conventional insulation layers to thin aerogel layers by exploiting the unique nanoscale pore structure of aerogels, effectively reducing the dimensional thickness while maintaining insulation performance
3Reliability
If aerogel materials are used to provide thermal insulation, then thermal resistance is improved and shielding is increased without substantially increasing thickness or weight, but the mechanical properties and compressibility need to be enhanced for battery module applications
Solution Approach 1:
The patent creates composite aerogel structures by combining aerogel particles or fibers with binding agents, foam matrices, or fabric substrates. This composite approach enhances mechanical strength and compressibility while preserving the low thermal conductivity of aerogel materials
Solution Approach 2:
The patent utilizes the porous structure of aerogels and incorporates it into composite materials with controlled porosity to maintain thermal insulation performance while improving mechanical properties through the porous framework
4Reliability
If insulation thickness is increased to provide effective thermal management with conventional materials, then fire propagation resistance is improved, but the space requirements for battery modules are exceeded
Solution Approach 1:
The patent changes the thermal conductivity parameter to extremely low values using aerogel materials, enabling the same fire propagation resistance with much smaller insulation thickness and thus preserving battery module space
Solution Approach 2:
The patent achieves superior insulation performance in a thin layer by exploiting the nanoscale structure of aerogels, effectively reducing the spatial volume required for insulation while maintaining fire propagation resistance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively controls heat propagation and fire protection in battery modules by maintaining low temperatures and reducing weight and thickness, while ensuring compressibility and resilience to accommodate cell expansion during charge/discharge cycles.
Implementation Method 1
Aerogels function as insulators primarily by minimizing conduction (low structural density results in tortuous path for energy transfer through the solid framework)
Implementation Method 2
convection (large pore volumes and very small pore sizes result in minimal convection)
Implementation Method 3
radiation (with IR absorbing or scattering dopants)
Data Source
AI summary
Aerogel-based components and systems for electric vehicle thermal management are provided. Exemplary embodiments include a heat control member. The heat control member can include reinforced aerogel compositions that are durable and easy to handle, have favorable performance for use as heat control members and thermal barriers for batteries, have favorable insulation properties, and have favorable reaction to fire, combustion and flame-resistance properties. Also provided are methods of preparing or manufacturing such reinforced aerogel compositions. In certain embodiments, the composition has a silica-based aerogel framework reinforced with a fiber and including one or more opacifying additives.