Battery Cell Thermal Barrier With Intumescent Runaway Containment
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Solution Overview
Problem
In hybrid or electric vehicles, thermal runaway in battery cells can lead to rapid temperature increases, causing heat propagation between cells, which existing insulating materials fail to effectively manage, potentially resulting in further thermal runaway and battery failure.
Innovation Solution
The integration of thermal barriers with a combination of thermal insulators and endothermic intumescent materials between battery cells, which absorb heat and expand to engage the cells, slowing down thermal propagation and reducing temperature increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing thermal insulating materials are used between battery cells, then thermal propagation is slowed, but the materials fail to effectively manage rapid temperature increases during thermal runaway
Solution Approach 1:
The thermal barrier is constructed as a composite structure comprising multiple layers: a first thermal insulator, an endothermic and intumescent layer, and a second thermal insulator. This composite configuration combines materials with different thermal properties to achieve both thermal insulation and active heat absorption, effectively managing rapid temperature increases during thermal runaway while maintaining structural integrity
Solution Approach 2:
The endothermic and intumescent layer utilizes phase transition mechanisms to manage thermal runaway. The material undergoes endothermic decomposition and intumescent expansion when exposed to high temperatures, actively absorbing heat and transforming from a compact state to an expanded insulating state, thereby providing dynamic thermal protection during critical temperature events
2Reliability
If thermal barriers are added between cells to reduce heat transfer, then thermal propagation time is prolonged, but device complexity increases
Solution Approach 1:
The thermal barrier is segmented into distinct functional layers: first and second thermal insulators providing baseline insulation, and an intermediate endothermic and intumescent layer providing active thermal management. This segmentation allows each layer to perform its specific function optimally while maintaining a compact overall structure that integrates seamlessly between battery cells
Solution Approach 2:
The endothermic and intumescent layer acts as an intermediary between the first and second thermal insulators, providing active heat absorption and dynamic insulation enhancement. This intermediary layer bridges the gap between passive insulation materials, creating a synergistic thermal barrier system that manages thermal runaway more effectively than simple insulation alone
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
This configuration significantly prolongs the time for thermal propagation between cells, allowing for safer operation by reducing the likelihood of subsequent cells entering thermal runaway at lower states of charge and minimizing heat transfer, thereby enhancing battery safety and performance.
Implementation Method 1
The endothermic and intumescent layer is configured to, in response to an increase in temperatures of the first and second of the cells and heat generated by the first and second of the cells consuming the first and second thermal insulators, expand, engage the first and second of the cells, and absorb the heat generated by the first and second of the cells
Implementation Method 2
The endothermic and intumescent material is configured to, in response to an increase in a temperature of the cell and heat generated by the cell consuming the thermal insulator, (i) expand, (ii) engage the exterior surface of the cell, and (iii) absorb the heat generated by the cell
Data Source
AI summary
A battery includes a cell and a thermal barrier. The cell is configured to store and discharge electrical energy. The thermal barrier is disposed along an exterior surface of the cell. The the thermal barrier includes a thermal insulator. The thermal barrier also includes an endothermic and intumescent material. The thermal insulator engages the exterior surface of the cell. The endothermic and intumescent material is disposed on an exterior of the thermal insulator such that the thermal insulator is disposed between the cell and the endothermic and intumescent material. The endothermic and intumescent material is configured to, in response to an increase in a temperature of the cell and heat generated by the cell consuming the thermal insulator, (i) expand, (ii) engage the exterior surface of the cell, and (iii) absorb the heat generated by the cell.