Aerogel Battery Insulation Sheet Composition for Dust-Free Heat Blocking
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Solution Overview
Problem
Conventional battery insulation materials face challenges in providing effective thermal insulation and durability while preventing dusting, as they are often brittle and difficult to process into thin, shaped forms, and existing solutions like organic foams are prone to fire and have high thermal conductivity.
Innovation Solution
An aerogel composition comprising a solvent, fibrous support, and functional materials like a binder and dispersant, which is formulated to have a specific weight ratio and content range, is used to create a battery insulation sheet with excellent heat insulation and durability, preventing dusting during manufacturing and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional plate materials or insulating resin plates are used for battery insulation, then thermal insulation between adjacent cells is achieved, but the materials are brittle and difficult to process into thin, shaped forms
Solution Approach 1:
The patent uses a composite structure consisting of aerogel particles dispersed in a binder matrix. The aerogel provides thermal insulation while the binder provides flexibility and processability, resolving the contradiction between thermal insulation performance and ease of manufacturing into thin shaped forms.
Solution Approach 2:
The patent changes the physical state and composition parameters by using aerogel particles with controlled size distribution (0.1-100 μm) and combining them with specific binder materials in optimized ratios, enabling the material to be processed into thin sheets while maintaining thermal insulation properties.
2Ease of manufacture
If organic foam materials are used for battery insulation, then ease of processing is improved, but fire resistance deteriorates and thermal conductivity increases
Solution Approach 1:
The patent employs aerogel, an ultra-porous material with porosity exceeding 90%, as the insulating component. The porous structure provides excellent thermal insulation with low thermal conductivity while the inorganic nature of aerogel ensures fire resistance, overcoming the limitations of organic foams.
Solution Approach 2:
The patent uses a binder material that can be easily processed and applied, accepting that the binder itself may not provide long-term structural stability but serves its purpose during manufacturing and application, while the aerogel particles provide the enduring fire-resistant insulation property.
3Temperature
If aerogel is used for battery insulation, then heat insulation property and durability are improved, but dusting occurs during manufacturing and use
Solution Approach 1:
The patent uses a binder material as an intermediary substance that coats and binds the aerogel particles together. This binder matrix prevents aerogel particles from detaching and becoming dust during handling and manufacturing processes, while allowing the aerogel to maintain its thermal insulation function.
Solution Approach 2:
The binder creates a flexible matrix that encapsulates the aerogel particles, forming a coherent structure that resists particle detachment. This flexible binding approach prevents dusting while maintaining the thermal insulation performance of the aerogel composition.
4Strength
If fibrous support is added to aerogel composition, then mechanical strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the fibrous support function with the binder matrix by incorporating fibers directly into the binder-aerogel composition. This integration approach provides mechanical strength enhancement without requiring separate fibrous support layers or complex multi-step manufacturing processes.
Solution Approach 2:
The patent optimizes the fiber content parameter within a specific range (0.1-10 wt%) and controls fiber dimensions to achieve adequate mechanical strength while avoiding excessive complexity in handling and processing the fibrous aerogel composition during manufacturing.
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 aerogel composition achieves excellent heat insulation and durability for battery insulation sheets, reducing manufacturing costs and preventing dust generation, while maintaining effective thermal performance and mechanical strength.
Implementation Method 1
thermal runaway of one cell due to overheating for various reasons may adversely affect other, adjacent cells. Thus, adjacent cells should be thermally insulated from each other.
Implementation Method 2
aerogel composition having an excellent heat insulation property
Implementation Method 3
The binder may include an aqueous polymer binder, and the aqueous polymer binder may include at least one selected from the group consisting of an aqueous polymer, an anionic water-soluble polymer, a cationic water-soluble polymer, and a water-dispersible polymer.
Implementation Method 4
The dispersant may include at least one selected from the group consisting of a surfactant and a phosphate-based salt.
Data Source
AI summary
An aerogel composition for a battery insulation sheet is provided. The aerogel composition comprising: a solvent; a fibrous support; an aerogel; and a functional material including a binder, a dispersant, or a combination thereof. With respect to a total solid content of the aerogel composition, the fibrous support is present in a content range of 5 wt % to 70 wt %, the aerogel is present in a content range of 10 wt % to 90 wt %, and the functional material is present in a content range of 0.5 wt % to 20 wt %.