Aerogel Heat Control Layers for EV Battery Fire Containment
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Solution Overview
Problem
Conventional insulation materials for lithium ion battery modules are inadequate in providing effective thermal management and fire protection due to their low thermal resistance and high thickness requirements, which conflict with the need for compact and lightweight designs.
Innovation Solution
Development of reinforced aerogel compositions with improved compressibility, thermal resistance, and fire reaction properties, including layers of aerogel with additives and thermally capacitive materials, to create heat control members that maintain low thermal conductivity and high fire resistance.
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 insulation thickness must be increased to achieve effective thermal management
Solution Approach 1:
The patent changes the thermal conductivity parameter by introducing aerogel materials with ultra-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 performance with significantly reduced thickness
Solution Approach 2:
The patent uses composite aerogel structures combining different aerogel materials (silica aerogel, carbon aerogel, organic aerogel) with complementary properties to achieve both ultra-low thermal conductivity and adequate mechanical strength for battery separation applications
2Reliability
If conventional insulation materials are used to provide thermal containment, then fire propagation protection is achieved, but the overall weight of the battery module increases
Solution Approach 1:
The patent changes the density parameter by using aerogel materials with extremely low density (0.01-0.5 g/cm³), which are 2-6 times lighter than conventional insulation materials. This enables fire propagation protection with minimal weight penalty
Solution Approach 2:
The patent employs porous aerogel structures with high porosity (80-99%) that provide excellent thermal insulation performance per unit weight, achieving fire propagation protection while minimizing the weight of the battery module
3Reliability
If insulation thickness is increased to provide effective thermal management, then heat propagation resistance is improved, but the space requirements for battery modules are exceeded
Solution Approach 1:
The patent changes the thermal conductivity parameter to ultra-low values (k < 0.03 W/m·K) using aerogel materials, which provides superior heat propagation resistance in a compact thickness, thereby reducing the volume occupied by insulation in the battery module
Solution Approach 2:
The patent transitions from conventional thick insulation layers to thin aerogel films, effectively moving the solution to another dimension of thickness, which allows adequate thermal management without exceeding battery module space requirements
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 reinforced aerogel compositions effectively control heat propagation and fire protection while minimizing material thickness and weight, ensuring safe and efficient thermal management in battery modules.
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
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AI summary
The present disclosure relates to a heat control member, a battery module comprising the heat control member and a battery pack. The heat control member comprises at least two layers of an aerogel composition, wherein the aerogel composition includes a reinforcement material, the aerogel composition including one or more additives, the additives being present at a level of at least about 5 to 20 percent by weight of the aerogel composition; at least one compliant member being layer of compliant material disposed between a first layer of the aerogel composition and a second layer of the aerogel composition; a second layer of a thermally capacitive material disposed at a major surface first layer of the aerogel composition; and a second layer of a thermally capacitive material disposed at a major surface of the second layer of the aerogel composition.