Aerogel Battery Insulation Sheet With Meltable Binder Adhesion

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Solution Overview

Problem

Existing rechargeable lithium batteries face challenges in reducing heat propagation and transfer between adjacent cells, necessitating improved heat insulation, adhesion, dust resistance, and flexibility in battery modules.

Innovation Solution

A heat insulating sheet for rechargeable lithium batteries comprising a first base layer and an aerogel-containing layer, with a meltable binder having a melting point of 30° C. to 80° C., enhancing adhesion and flexibility, and including fibrous support and aerogel for improved heat insulation and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional heat insulating materials are used between battery cells, then heat insulation performance is improved, but adhesion between layers deteriorates

Engineering Contradiction:

Improveheat insulation performanceVSAvoidadhesion between base layer and aerogel-containing layer

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent uses a composite structure consisting of a base layer and an aerogel-containing layer. The aerogel-containing layer comprises a fibrous support mixed with aerogel particles and binders, creating a composite material that combines the heat insulation properties of aerogel with the structural integrity of the fibrous support, achieving both thermal insulation and adhesion requirements

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent specifies that the binder in the aerogel-containing layer has a melting point between 30°C and 80°C. This parameter control allows the binder to remain flexible at operating temperatures while providing adequate adhesion, and to melt at elevated temperatures for potential re-bonding or safety release, thus resolving the adhesion contradiction

Inventive Principle:

Principle #35Parameter changes

2Temperature

If aerogel-containing layer with high aerogel content is used, then heat insulation performance is improved, but flexibility and punchability deteriorate

Engineering Contradiction:

Improveheat insulation performanceVSAvoidflexibility and punchability

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The patent utilizes aerogel, a highly porous material with exceptional insulation properties, as the primary heat insulating component. The porous structure of aerogel provides superior thermal resistance while maintaining low density, contributing to flexibility when properly integrated into the composite structure

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The fibrous support acts as a flexible matrix that reinforces the brittle aerogel particles. This composite approach allows the aerogel-containing layer to maintain high aerogel content for insulation while the fibrous network provides the necessary flexibility and punchability for manufacturing and installation

Inventive Principle:

Principle #40Composite materials

3Strength

If strong adhesion between layers is achieved, then structural integrity is improved, but dust resistance deteriorates

Engineering Contradiction:

Improveadhesion between layersVSAvoiddust resistance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The aerogel-containing layer functions as a flexible intermediate film between the base layer and the aerogel particles. This thin film structure provides a smooth surface that resists dust accumulation while maintaining strong adhesion to the base layer, thus resolving the contradiction between adhesion and dust resistance

Inventive Principle:

Principle #30Flexible shells and thin films

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 provides enhanced heat insulation, adhesion, and dust resistance, while maintaining flexibility and ease of handling, effectively reducing heat transfer between battery cells.

Implementation Method 1

an aerogel-containing layer which includes a fibrous support, an aerogel, a first binder, and a second binder

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

the second binder is a meltable binder with a melting point that ranges from about 30° C. to about 80° C.

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250349942A1Heat insulating sheet for rechargeable lithium battery and rechargeable lithium battery module including the same

Publication Date: 2025.11.13 SAMSUNG SDI CO LTD

AI summary

Examples of the present disclosure relate to a heat insulating sheet for a rechargeable lithium battery, and a rechargeable lithium battery module including the heat insulating sheet. The heat insulating sheet for a rechargeable lithium battery includes a first base layer and an aerogel-containing layer that are stacked together. The aerogel-containing layer includes a fibrous support, an aerogel, a first binder, and a second binder, and the second binder is a meltable binder with a melting point that ranges from about 30° C. to about 80° C.