Multilayer Thermal Laminate with Aerogel for Battery Enclosures
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Solution Overview
Problem
Existing battery cell enclosures face challenges in managing thermal dissipation efficiently, leading to potential overheating and thermal inhomogeneity, which can limit the compactness and operational duration of portable information handling systems.
Innovation Solution
A multilayer thermal laminate is introduced, comprising a silica aerogel insulator, a graphite thermal conductor, a phase change material with a melting temperature range of 50-60°C, and a directional conductor such as a metal bar or heat pipe, which helps in effective heat transmission and distribution across the battery cell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional thermal management materials are used in battery cell enclosures, then the structure is simple and easy to manufacture, but thermal dissipation efficiency is poor leading to overheating and thermal inhomogeneity
Solution Approach 1:
The thermal management system is divided into three distinct functional layers: an aerogel insulator layer for thermal isolation, a phase change material layer for thermal regulation, and a directional conductor layer for heat distribution. Each layer performs a specific thermal function, collectively resolving the contradiction by achieving superior thermal dissipation through segmented functional specialization rather than a single homogeneous material.
Solution Approach 2:
The invention employs a composite laminate structure combining three different material types with complementary thermal properties: aerogel (insulator), phase change material (thermal regulator), and directional conductor (heat transmitter). This composite approach enables the system to simultaneously provide insulation, thermal regulation, and directional heat transfer, achieving high thermal dissipation efficiency that outweighs the increased structural complexity.
2Loss of energy
If thermal insulation is increased to prevent heat loss, then energy efficiency improves, but localized hotspots form due to thermal inhomogeneity
Solution Approach 1:
Different regions of the thermal management system are assigned different material properties: the aerogel layer provides uniform insulation across the battery surface, the phase change material layer absorbs excess heat locally where it accumulates, and the directional conductor layer strategically channels heat away from hotspot regions. This spatial differentiation of thermal properties prevents localized hotspots while maintaining overall energy efficiency.
Solution Approach 2:
The phase change material layer undergoes phase transition (melting/freezing) at specific temperature ranges to actively regulate thermal energy. When hotspots form, the phase change material absorbs excess heat through melting, preventing temperature runaway. This dynamic phase transition mechanism maintains thermal distribution uniformity while preserving thermal energy retention, directly resolving the contradiction between insulation and thermal homogeneity.
3Volume of moving object
If battery cell enclosure size is reduced for compactness, then device portability improves, but thermal management capability deteriorates
Solution Approach 1:
The thermal management system transitions from volumetric heat management to surface-based directional heat conduction. The directional conductor layer extends beyond the battery cell boundaries in specific dimensions, creating thermal pathways that efficiently dissipate heat laterally across the enclosure surface. This dimensional approach enables effective thermal management in compact volumes by utilizing surface area for heat dissipation rather than relying solely on internal volume.
Solution Approach 2:
The three thermal management layers are nested concentrically around the battery cell: the aerogel insulator forms the innermost layer directly contacting the battery, the phase change material layer is nested around the aerogel, and the directional conductor layer forms the outermost protective shell. This nested configuration maximizes thermal management efficiency within minimal volume by ensuring each layer contributes its specific function in a compact, space-efficient arrangement.
4Stability of the object's composition
If thermal conductors are added to improve heat distribution, then thermal inhomogeneity is reduced, but heat transmission in unwanted directions increases
Solution Approach 1:
The aerogel insulator layer serves as a thermal intermediary between the battery cell and the external environment. It selectively transmits heat to the phase change material and directional conductor layers while blocking unwanted heat transmission paths. This intermediary layer ensures that thermal conductors distribute heat uniformly where needed without creating harmful thermal pathways in unwanted directions, resolving the contradiction between thermal uniformity and harmful heat transmission.
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 multilayer thermal laminate effectively insulates, conducts, and stores heat, preventing localized hotspots and ensuring even thermal distribution, thereby enabling a more compact and durable battery cell enclosure that maintains optimal operating temperatures.
Implementation Method 1
a first layer at least partially enclosing a battery cell, the first layer comprising an aerogel insulator
Implementation Method 2
a third layer at least partially enclosing the second layer, the third layer comprising a thermal storage medium
Implementation Method 3
the phase change material may have a melting temperature range between 50 C and 60 C
Implementation Method 4
a directional conductor embedded within the third layer, the directional conductor extending beyond a length of the battery cell to transmit heat over the length of the battery cell
Data Source
AI summary
A multilayer thermal laminate with aerogel is used for a battery cell enclosure to improve thermal properties and to reduce thermal inhomogeneity in the form of localized hotspots that exceed a desired rated temperature, thereby enabling a more compact design within rated thermal design limits for a given electrical performance.