Inorganic-Filled Insulating Sheet for Battery Cell Thermal Isolation
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Solution Overview
Problem
Existing methods for manufacturing assembled batteries, such as resin potting, face challenges in controlling resin thickness, preventing bubble formation, and ensuring safety due to resin flow into unnecessary areas, which complicates the process and increases mass, making it difficult to enhance safety and dimensional accuracy.
Innovation Solution
An insulating sheet formed from a resin composition containing an inorganic filler is interposed between battery cells, providing electrical insulation, flexibility, and improved heat dissipation, eliminating the need for resin curing and minimizing mass increase, while allowing for controlled thickness and enhanced dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin potting is used to improve safety, then thermal runaway prevention is improved, but manufacturing precision deteriorates due to difficulty in controlling resin thickness uniformity
Solution Approach 1:
The patent changes the physical state of the insulating material from liquid resin to solid sheet form. This parameter change enables precise thickness control during manufacturing while maintaining the safety function, as the sheet thickness can be uniformly controlled during production without the variability inherent in liquid resin pouring and curing processes
Solution Approach 2:
The patent uses composite materials by incorporating inorganic fillers (such as aluminum hydroxide, magnesium hydroxide, or silica) into the resin composition of the insulating sheet. This composite structure provides both the safety function of thermal runaway prevention and the manufacturing advantage of controlled thickness, as the inorganic fillers enhance thermal stability while the sheet form enables precise dimensional control
2Reliability
If resin potting is used to improve safety, then thermal runaway prevention is improved, but device complexity increases due to curing process requirements
Solution Approach 1:
The patent applies preliminary action by pre-forming the insulating sheet with controlled thickness and properties before assembly. The sheet is manufactured in advance with precise thickness control and inorganic filler distribution, eliminating the need for on-site resin pouring, bubble removal, and curing processes during battery assembly, thus reducing device complexity
Solution Approach 2:
The patent replaces the chemical curing system with a mechanical assembly system. Instead of using liquid resin that requires chemical curing (involving temperature control, time delays, and inspection), the solid insulating sheet is simply positioned and secured between battery cells through mechanical means, dramatically simplifying the manufacturing process
3Reliability
If resin potting is used to improve safety, then thermal runaway prevention is improved, but weight increases due to resin flow into unnecessary parts
Solution Approach 1:
The patent applies local quality by positioning the insulating sheet precisely only where insulation is needed between battery cells. The sheet is cut or shaped to match the specific geometry of the battery cell interfaces, ensuring that the inorganic filler-containing material is localized to critical thermal isolation zones rather than being distributed throughout the entire battery assembly, thus minimizing unnecessary weight
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 insulating sheet improves safety by preventing thermal runaway and reducing mass, while maintaining dimensional accuracy and process efficiency, effectively addressing the limitations of resin potting methods.
Implementation Method 1
an insulating sheet which is to be interposed between battery cells having planar surfaces facing each other
Implementation Method 2
a heat-absorbing material is provided between a battery cell and a fixing member disposed to surround the peripheral surface of the battery cell, and the heat-absorbing material is provided between opposing surfaces of adjacent battery cells
Data Source
AI summary
The safety of an assembled battery is improved. An insulating sheet 10 is to be interposed between battery cells 20 having planar surfaces 34 facing each other and is formed of a resin composition containing an inorganic filler. An assembled battery 50 includes a plurality of battery cells 20 having planar surfaces 34 and the insulating sheet 10. The insulating sheet 10 is interposed in at least one facing section 36 of the plurality of battery cells 20 whose planar surfaces 34 are arranged to face each other.