Battery Module Composite Insulation for Flame Spread and Short-Circuit Risk
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Solution Overview
Problem
Conventional methods for preventing flame spread and ensuring safety in battery modules are inadequate, as they either fail to suppress flames during thermal runaway or compromise energy density and weight reduction due to the use of high-density, low-adhesive-strength materials like mica sheets or ceramic wool.
Innovation Solution
A battery module incorporating a flame-retardant composite material with an insulating layer containing an organic binder and an inorganic long fiber network, which includes woven fibers and an inorganic filler, effectively prevents short circuits and suppresses heat and flame spread while maintaining energy density and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If highly fire-resistant materials such as mica sheet or ceramic wool are provided in a battery module, then flame spread is suppressed, but dust or debris is generated causing short circuits or failures and long-term stability cannot be secured
Solution Approach 1:
The patent uses a composite material consisting of inorganic long fibers (such as glass fibers) embedded in a resin matrix. This composite structure combines the flame-retardant properties of inorganic materials with the dust-free characteristics of processed fibers, resolving the contradiction between flame suppression and long-term stability by preventing debris generation while maintaining fire resistance
2Object-affected harmful factors
If highly fire-resistant materials such as mica sheet or ceramic wool are provided in a battery module, then flame spread is suppressed, but the specific gravity is high and adhesive strength is low requiring thick adhesive layers which limits energy density improvement and weight reduction
Solution Approach 1:
The patent changes the physical parameters of the flame-retardant material by using processed inorganic long fibers with controlled length, diameter, and orientation within a resin matrix. This allows reduction of specific gravity compared to traditional mica or ceramic wool, while the fibers provide sufficient mechanical strength to use thin adhesive layers, thereby achieving weight reduction and improved energy density while maintaining flame suppression
3Temperature
If conventional cooling members are provided for cooling during battery operation, then heat generated during normal operation is cooled, but these methods do not function in thermal runaway situations such as cell explosion
Solution Approach 1:
The patent creates a flame-retardant composite material that serves dual functions: it provides thermal insulation during normal battery operation to assist cooling efforts, and actively suppresses flame spread during thermal runaway events. The inorganic long fiber network structure provides this universal protection across different operational conditions, making the same material effective for both routine thermal management and emergency fire suppression
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 effectively prevents short circuits and suppresses heat and flame spread during thermal runaway, ensuring long-term stability and improved safety without compromising energy density or weight reduction.
Implementation Method 1
an inorganic long fiber network which is formed by weaving a plurality of first fibers (wefts) arranged in a first direction and a plurality of second fibers (warps) arranged in a second direction intersecting the first direction
Implementation Method 2
an insulating layer containing an organic binder and an inorganic long fiber network
Data Source
AI summary
An exemplary embodiment of the present disclosure may provide a battery module including a plurality of secondary battery cells housed in a housing member, wherein a flame-retardant composite material is located between the plurality of secondary battery cells, and the flame-retardant composite material includes an insulating layer containing an organic binder and an inorganic long fiber network formed by weaving a plurality of first fibers (wefts) arranged in a first direction and a plurality of second fibers (warps) arranged in a second direction intersecting the first direction.