Fiber-Elastomer Battery Cell Mat for Heat Isolation and Swelling
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Solution Overview
Problem
Lithium ion battery systems face challenges in preventing overheating and thermal runaway, as well as managing volume expansion and electrical insulation between cells, which can lead to safety risks and system instability.
Innovation Solution
A thermal insulating mat made of an elastically deformable fiber-elastomer composite with ribs and a decoupled frame, designed to absorb pretensioning pressure and compensate for cell volume changes, while providing effective thermal and electrical insulation, is used between battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermal insulating fixture is provided between adjacent cells to prevent heat transfer, then thermal insulation performance is improved, but the device complexity and space requirements increase
Solution Approach 1:
The mat performs multiple functions simultaneously: thermal insulation between cells, electrical insulation between cells, mechanical compensation for cell volume changes, and structural support. This multi-functionality reduces the need for separate components, thereby simplifying the overall device complexity while maintaining effective thermal insulation.
Solution Approach 2:
The mat is made from composite materials that combine thermal insulation properties with electrical insulation properties and mechanical flexibility. This allows a single component to satisfy multiple requirements (thermal, electrical, and mechanical) without needing additional separate fixtures, thus improving thermal insulation without proportionally increasing device complexity.
2Productivity
If the battery cells are tightly packed to increase energy density, then productivity and space utilization are improved, but the risk of heat spread and thermal runaway increases
Solution Approach 1:
The mat acts as an intermediary layer between adjacent battery cells, providing thermal insulation that prevents heat spread while allowing the cells to be tightly packed. This intermediary layer enables high energy density configuration without proportionally increasing the risk of thermal runaway, as the mat blocks heat transfer pathways between cells.
3Temperature
If a rigid thermal insulating structure is used to prevent heat transfer, then thermal insulation performance is improved, but the ability to compensate for cell volume changes deteriorates
Solution Approach 1:
The mat employs a dynamic, flexible structure rather than a rigid one. The mat can deform and adapt its shape to accommodate cell expansion and contraction during charging and discharging cycles, while still maintaining effective thermal insulation. This dynamic adaptability allows the mat to provide both thermal protection and volume change compensation simultaneously.
4Temperature
If additional insulation layers are added to improve thermal protection, then thermal insulation performance is improved, but the weight and volume of the battery system increase
Solution Approach 1:
The mat provides multiple protective functions (thermal insulation, electrical insulation, mechanical cushioning) in a single lightweight component, eliminating the need for multiple separate insulation layers. This multi-functionality achieves comprehensive thermal protection without proportionally increasing the battery system weight, as one integrated mat replaces what would otherwise require multiple separate components.
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 mat effectively limits heat transfer between cells, maintains dimensional stability, and ensures electrical insulation, thereby preventing overheating and ensuring the safety and longevity of the battery system.
Implementation Method 1
a thermal insulating mat (1) for the insulation of adjacent battery cells (2) in battery systems consisting of an elastically deformable base plate (7) made of a fiber-elastomer composite
Implementation Method 2
an elastically deformable base plate (7) made of a fiber-elastomer composite... capable, at the same time, of compensating for the system-inherent change in the battery cells (2)
Data Source
AI summary
The present invention relates to a thermal insulating mat (1) for insulating adjacent battery cells (2), in particular prismatic battery cells, in battery systems, comprising an elastically deformable base plate (7) made of a fiber-elastomer composite, wherein a defined number of ribs (8) are provided on both main surfaces of the base plate (7), extending parallel to one another and spaced apart from one another transversely over the main surfaces of the base plate (7), wherein the arrangement of ribs on the two main surfaces is surrounded by a bordering frame (10), and there is a gap (11) between the ribs (8) and the frame (10), wherein the fiber-elastomer composite of the base plate (7) is formed from an elastomer matrix with at least one intermediate layer of mineral fibers embedded therein, and wherein the thermally insulating mat at the same time is able to compensate for the change in volume of the battery cells inherent in the system as a result of the chemical ageing of the cell components and the cyclical expansion and contraction of the cells during charging and discharging.