Aerogel Insulation Sheet Structure for Battery Heat and Dust Control
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Solution Overview
Problem
High-capacity secondary batteries, such as lithium-ion batteries, face thermal runaway issues due to overheating, which can affect adjacent cells, necessitating effective thermal insulation between cells while maintaining mechanical strength and preventing dust generation during manufacturing and use.
Innovation Solution
A battery insulation sheet comprising a substrate with an aerogel layer that includes a fibrous support, aerogel, and a functional material with a binder and dispersant, where the aerogel layer's thickness and fibrous support diameter ratio is controlled to achieve excellent heat insulation and compressive properties, and the manufacturing process minimizes dust generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a plate or insulating resin plate is disposed between cells to electrically and thermally insulate adjacent cells, then thermal insulation between cells is improved, but mechanical strength and dusting property deteriorate
Solution Approach 1:
The patent uses a composite structure consisting of a substrate and an aerogel layer. The substrate provides mechanical strength while the aerogel layer provides thermal insulation. This composite material approach resolves the contradiction by combining materials with complementary properties - the substrate handles mechanical loads while the aerogel handles thermal insulation, achieving both requirements simultaneously.
Solution Approach 2:
The patent employs aerogel, a highly porous material with exceptional thermal insulation properties. The porous structure of aerogel creates numerous air pockets that impede heat transfer, providing superior thermal insulation. When combined with the substrate, this porous material achieves thermal insulation without compromising the overall mechanical strength of the insulating sheet.
2Temperature
If aerogel is used for thermal insulation, then heat insulation property is improved, but dust generation during manufacturing and use worsens
Solution Approach 1:
The patent uses a substrate as a flexible support structure that holds the aerogel in place. This substrate acts as a containment structure preventing the aerogel from breaking into dust particles during manufacturing and use. The aerogel is integrated with the substrate in a way that maintains its structural integrity while preserving its thermal insulation properties.
3Temperature
If aerogel layer thickness is increased to improve thermal insulation, then heat insulation property is improved, but compressive property deteriorates
Solution Approach 1:
The composite structure of substrate and aerogel layer allows optimization of both thermal insulation and compressive properties. The substrate provides structural support and compressive strength, while the aerogel layer provides thermal insulation. This division of functional responsibilities enables the system to achieve good thermal insulation without sacrificing compressive property, even at optimized thicknesses.
Solution Approach 2:
The patent optimizes the thickness of the aerogel layer to achieve the right balance between thermal insulation and compressive property. By carefully controlling this parameter, the design achieves sufficient thermal insulation while maintaining adequate compressive strength for battery module applications.
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 a battery insulation sheet with enhanced heat insulation and compressive properties, reduces manufacturing costs, and prevents dust generation, thereby improving safety and durability in battery modules by effectively controlling heat transfer and withstanding explosion-induced pressure.
Implementation Method 1
a battery insulation sheet including a substrate, and an aerogel layer on the substrate... excellent or suitable heat insulation
Data Source
Figure 1~2
Figure 3~4
AI summary
A battery insulation sheet includes a substrate, and an aerogel layer on the substrate, wherein the aerogel layer includes a fibrous support; an aerogel; and a functional material including a binder, a dispersant, or a combination thereof, and satisfies Formula 1 below: 50≤A≤100,000,A=Ti/Ds, wherein, in Formula 1, Ti denotes a thickness of the aerogel layer, and Ds denotes an average diameter of the fibrous support.