Traction Battery Case Shielding for Thermal Runaway Containment
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Solution Overview
Problem
Existing battery boxes for traction batteries face challenges in preventing thermal runaway and mechanical protection, with high-temperature-resistant materials offering little mechanical protection and deteriorating under mechanical stress, and existing insulation methods failing to effectively prevent flame penetration and heat transfer.
Innovation Solution
A two-layer shielding element is positioned between battery modules, comprising a first outer layer made of lightweight aluminum and a second outer layer made of high-temperature-resistant steel, optionally with an insulation layer in between, designed to delay or prevent flame penetration and heat transfer, while being adaptable to the 3D shape of the battery box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high-temperature-resistant materials are used to prevent thermal runaway, then thermal protection is improved, but mechanical protection is insufficient and the protective effect diminishes over time under mechanical stress
Solution Approach 1:
The patent applies composite materials by combining a metal layer (steel or aluminum) with an insulating layer (ceramic, glass fiber, or mineral wool) to create a shielding element that provides both mechanical strength and thermal insulation. This composite structure resolves the contradiction by integrating the advantages of both material types: the metal provides structural integrity while the insulating layer provides thermal protection.
Solution Approach 2:
The shielding element is positioned locally between battery modules or between battery modules and the battery box wall, providing targeted thermal and mechanical protection where it is most needed. This local placement optimizes the protective effect while reducing overall material usage and maintaining mechanical strength in critical areas.
2Strength
If a single metal layer is used for the shielding element, then mechanical protection is improved, but thermal insulation effectiveness is reduced
Solution Approach 1:
The patent uses composite materials by combining a metal layer (steel or aluminum) with an insulating layer (ceramic, glass fiber, or mineral wool) to create a shielding element that provides both mechanical strength and thermal insulation. This composite structure resolves the contradiction by integrating the advantages of both material types: the metal provides structural integrity while the insulating layer provides thermal protection.
3Temperature
If thick insulating layers are used to prevent heat transfer, then thermal insulation is improved, but mechanical stability and 3D shape maintenance deteriorate
Solution Approach 1:
The patent uses composite materials by combining a metal layer (steel or aluminum) with an insulating layer (ceramic, glass fiber, or mineral wool) to create a shielding element that provides both mechanical strength and thermal insulation. This composite structure resolves the contradiction by integrating the advantages of both material types: the metal provides structural integrity while the insulating layer provides thermal protection.
Solution Approach 2:
The shielding element can be designed as a thin-walled structure where the metal layer provides the necessary mechanical stability and 3D shape maintenance, while the insulating layer (even when thin) provides adequate thermal insulation when combined with the reflective properties of the metal surface.
4Weight of moving object
If lightweight materials are used for the shielding element, then weight is reduced, but mechanical protection and flame penetration resistance are insufficient
Solution Approach 1:
The patent uses composite materials by combining a metal layer (steel or aluminum) with an insulating layer (ceramic, glass fiber, or mineral wool) to create a shielding element that provides both mechanical strength and thermal insulation. This composite structure resolves the contradiction by integrating the advantages of both material types: the metal provides structural integrity while the insulating layer provides thermal protection.
Solution Approach 2:
The shielding element is positioned locally between battery modules or between battery modules and the battery box wall, providing targeted thermal and mechanical protection where it is most needed. This local placement optimizes the protective effect while reducing overall material usage and maintaining mechanical strength in critical areas.
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 shielding element effectively prevents thermal runaway from spreading to adjacent modules, maintains battery modules within their nominal temperature range, and provides mechanical protection, delaying flame penetration into the vehicle for at least 5 minutes, while being lightweight and cost-effective.
Implementation Method 1
a first outer metallic layer (11) and a second outer metallic layer (12)... delaying flame penetration into the vehicle for at least 5 minutes
Implementation Method 2
designed to delay or prevent flame penetration and heat transfer
Data Source
Figure 1A~1C
Figure 2~3
Figure 4~5
AI summary
The invention relates to a battery case for a traction battery, and to the use thereof to hold traction batteries in vehicles.