Aerogel Insulation Molding for Elastic Battery Pack Spacers
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Solution Overview
Problem
Conventional heat-insulating materials for battery packs lose elasticity due to repeated deformation caused by the expansion and contraction of battery cells, leading to reduced restorability and inability to maintain the desired biasing force, which can result in misalignment of battery cells.
Innovation Solution
A manufacturing method for heat-insulating material using aerogel that includes a heat treatment process to remove organic components at a temperature higher than their softening point, allowing the aerogel to maintain its elasticity and improve thermal insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat-insulating material is used to suppress heat transfer between battery cells, then thermal insulation property is improved, but elasticity decreases after repeated deformation due to battery cell expansion and contraction
Solution Approach 1:
The patent applies parameter changes by controlling the organic component content within specific ranges (1-10 mass% of aerogel) and applying heat treatment at temperatures of 60°C or higher. These parameter adjustments optimize the balance between thermal insulation and elasticity, allowing the material to maintain both properties after repeated deformation cycles.
Solution Approach 2:
The patent uses composite materials by combining aerogel particles with organic components to create a heat-insulating material that leverages the low thermal conductivity of aerogel while the organic component provides flexibility and elastic recovery. This composite structure resolves the contradiction between thermal insulation and elasticity.
2Ease of manufacture
If organic component is added to improve elasticity and workability, then ease of manufacture is improved, but thermal insulation property deteriorates due to increased thermal conductivity
Solution Approach 1:
The patent precisely controls the organic component content within 1-10 mass% of aerogel and applies heat treatment at 60°C or higher. These parameter optimizations minimize the thermal conductivity contribution from organic components while maintaining sufficient workability and elastic recovery during manufacturing and application.
Solution Approach 2:
The patent applies heat treatment to remove or decompose volatile organic components after molding, extracting the harmful thermal conduction pathway while preserving the beneficial elastic properties. This extraction process reduces thermal conductivity while maintaining the material's workability and formability.
3Quantity of substance
If aerogel particles are pressurized during molding, then density is improved, but elasticity decreases due to collapse of voids between particles
Solution Approach 1:
The patent applies local quality by introducing organic components specifically in the void spaces between aerogel particles. This localized addition maintains the high-density structure from pressurization while the organic component in the voids provides elastic recovery capability, preventing complete collapse of the porous structure.
Solution Approach 2:
The patent creates a composite structure where aerogel particles form the dense skeleton and organic components fill the interstitial voids. This composite architecture allows the material to achieve high density through pressurization while the organic phase provides elastic recovery, resolving the contradiction between density and elasticity.
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 method produces a heat-insulating material that maintains elasticity and thermal insulation properties even with repeated deformation, effectively preventing battery cell misalignment and enhancing thermal insulation at high temperatures.
Implementation Method 1
a heat treatment process of holding the obtained molded body at a temperature equal to or higher than a softening point of the organic component
Implementation Method 2
This fine porous structure mainly suppresses conduction and convection among the three forms of heat transfer (conduction, convection, and radiation)
Data Source
AI summary
Provided is a manufacturing method for a heat-insulating material using aerogel. The manufacturing method for the heat-insulating material includes a composition manufacturing process of manufacturing a composition having aerogel and an organic component; a molding process of manufacturing a molded body by pressurizing the composition; and a heat treatment process of holding the obtained molded body at a temperature equal to or higher than a softening point of the organic component.