Aerogel Battery Insulation Sheet Without Adhesive Layers
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Solution Overview
Problem
Existing battery insulation methods, such as using plates or insulating resin sheets, are inadequate in providing effective thermal isolation and durability between high-capacity cells in secondary batteries, which can lead to thermal runaway and adverse effects on adjacent cells.
Innovation Solution
A battery insulation sheet is developed with a laminated structure comprising a first substrate, an aerogel layer, and a second substrate, where the aerogel layer directly faces the substrates without an additional adhesive layer, and is formulated to satisfy specific density ratios under varying pressures, enhancing thermal insulation, durability, and compressibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate adhesive layer is provided between the aerogel layer and substrates, then bonding strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The aerogel layer is directly bonded to the substrates without an intermediate adhesive layer, merging the insulation function and bonding function into a single component. This eliminates the adhesive layer while maintaining structural integrity through direct contact and bonding between the aerogel and substrate surfaces.
Solution Approach 2:
The adhesive layer is completely removed from the structure. By extracting this intermediate component, the design simplifies the manufacturing process while relying on the inherent bonding properties of the aerogel material and substrate interface to provide sufficient adhesion.
2Temperature
If conventional insulating materials are used, then manufacturing simplicity is maintained, but thermal insulation performance is insufficient
Solution Approach 1:
The insulation structure uses a composite of aerogel material sandwiched between two substrates. The aerogel provides superior thermal insulation properties compared to conventional materials, while the substrate-aerogel-substrate composite structure maintains manufacturability through direct lamination without requiring complex assembly processes.
3Strength
If aerogel layer is compressed to improve contact with substrates, then bonding is improved, but volume and insulation performance may deteriorate
Solution Approach 1:
The aerogel layer's physical parameters (density, compressibility, thermal conductivity) are optimized to achieve the right balance between contact bonding and insulation performance. By controlling the aerogel's mechanical properties and compression characteristics, sufficient contact with substrates is achieved while maintaining adequate thickness and insulation capability.
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 proposed battery insulation sheet achieves improved thermal insulation, durability, and compressibility, while reducing manufacturing costs and minimizing dust generation during processing and use, thereby effectively preventing thermal runaway between adjacent cells.
Implementation Method 1
it may be desirable to thermally isolate neighboring cells from each other
Implementation Method 2
PA indicates the mass per unit volume (g/cm3) of the aerogel layer after a pressure of 0 kN, equivalent to no pressure, is vertically applied to the aerogel layer, and PB indicates the mass per unit volume (g/cm3) of the aerogel layer after a pressure of 5 kN is vertically applied to the aerogel layer
Data Source
AI summary
Example embodiments include a battery insulation sheet having a structure in which a first substrate, an aerogel layer, and a second substrate are laminated, wherein opposite surfaces of the aerogel layer is in contact with the first substrate or the second substrate adjacent thereto. Example embodiments also include a method of manufacturing a battery insulation sheet, and a battery module including the battery insulation sheet.