Aerogel Insulation Pad Structure for Battery Thermal Runaway Blocking
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Solution Overview
Problem
Existing technologies face challenges in preventing thermal runaway in battery packs, particularly due to the limitations of existing materials at high temperatures and their impact on battery performance and weight.
Innovation Solution
The development of an insulation pad comprising a first and second thermal protection layer made of inorganic materials, with a thermal insulation layer in between, containing aerogel particles, a binder material, nanofibers, a surfactant, and a pigment material, which effectively blocks heat transfer and withstands high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer organic materials are used for thermal insulation in battery packs, then ease of manufacture is improved, but thermal resistance at high temperatures above 450°C deteriorates because the materials are completely decomposed
Solution Approach 1:
The patent applies composite materials by combining inorganic materials (such as ceramic fibers, mica, or glass wool) with polymer organic materials to create a thermal insulation layer that maintains both ease of manufacture and high-temperature thermal resistance. The inorganic materials provide structural stability and heat resistance above 450°C, while the polymer matrix ensures processability and manufacturing convenience.
Solution Approach 2:
The patent changes the material composition parameters by introducing flame retardant additives and inorganic fillers into the polymer matrix. This modifies the thermal decomposition characteristics of the material, raising the temperature at which the material maintains its integrity and preventing complete decomposition at temperatures above 450°C.
2Reliability
If insulation is inserted between cells or groups of cells to reduce heat transfer, then thermal protection is improved, but weight reduction and energy capacity increase are limited
Solution Approach 1:
The patent employs porous materials such as aerogels or foam structures as thermal insulation layers between battery cells. These materials provide excellent thermal insulation properties with extremely low density, thereby protecting against heat transfer while minimizing added weight and maximizing energy capacity.
Solution Approach 2:
The patent uses thin-film insulation materials that provide effective thermal barrier properties with minimal thickness. These thin films reduce heat transfer between cells while occupying minimal space and adding minimal weight, thus preserving energy capacity and achieving weight reduction.
3Reliability
If flame retardant additives are added to the electrolyte or non-flammable electrolytes are used, then thermal runaway prevention is improved, but lifespan and electrochemical performance deteriorate
Solution Approach 1:
The patent segments the thermal protection function into two separate components: the electrolyte maintains its original composition for optimal electrochemical performance and lifespan, while a dedicated thermal insulation layer containing flame retardant materials or inorganic barriers is inserted between battery cells. This segmentation allows thermal runaway prevention without compromising electrolyte performance.
Solution Approach 2:
The patent introduces an intermediary thermal insulation layer between battery cells that acts as a physical barrier to heat transfer. This intermediary layer prevents thermal runaway propagation while allowing the electrolyte to maintain its original properties for optimal lifespan and electrochemical performance.
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 insulation pad effectively suppresses thermal runaway in battery packs by providing excellent thermal protection and insulation properties, while being easy to manufacture and integrate into battery packs, thus enhancing safety and performance.
Implementation Method 1
a thermal insulation layer disposed between the first and second thermal protection layers, and including aerogel particles
Implementation Method 2
including aerogel particles, a binder material, a nanofiber, a surfactant, and a pigment material
Implementation Method 3
a first thermal protection layer composed of an inorganic material; a second thermal protection layer spaced apart from the first thermal protection layer and composed of an inorganic material
Data Source
AI summary
Provided is an insulation pad for preventing heat transfer including a first thermal protection layer composed of an inorganic material, a second thermal protection layer spaced apart from the first thermal protection layer and composed of an inorganic material, and a thermal insulation layer disposed between the first and second thermal protection layers, and including aerogel particles, a binder material, a nanofiber, a surfactant, and a pigment material.