Non-Uniform Thermal Barrier Assembly for Battery Cell Edge Insulation

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Solution Overview

Problem

Existing traction battery packs in electrified vehicles face challenges in managing thermal energy transfer within the battery cell stack, which can lead to thermal events and affect the performance and safety of the vehicle.

Innovation Solution

The implementation of a thermal barrier assembly with a structural barrier and thermal resistance material layers, each with non-uniform thicknesses, to compartmentalize the battery cell stack and inhibit thermal energy transfer. The thermal resistance material layers, which can include aerogel or mica sheets, are strategically thickened at the outboard edges to enhance thermal resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If uniform thickness thermal barrier assembly is used, then manufacturing is simple, but thermal resistance at critical edges is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidthermal resistance at edges

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The thermal resistance material layer is designed with non-uniform thickness, being thicker at the outboard edges and thinner at the mid-portion. This local variation in thickness provides enhanced thermal resistance precisely where heat transfer is most critical (at the edges adjacent to battery cells) while maintaining manufacturing feasibility through a single-layer construction approach.

Inventive Principle:

Principle #3Local quality

2Reliability

If non-uniform thickness thermal resistance material layer is used, then thermal resistance at edges is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal resistance at edgesVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If thermal barrier assembly compartmentalizes battery cell stack, then thermal energy transfer is inhibited, but device complexity increases

Engineering Contradiction:

Improvethermal energy transferVSAvoidassembly structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The thermal barrier assembly is designed to partition the battery cell stack into separate compartments, physically isolating adjacent battery cells. This segmentation prevents thermal runaway propagation by creating thermal barriers between cells, thereby inhibiting the transfer of harmful thermal energy while maintaining a relatively simple overall assembly structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thermal barrier assembly combines multiple materials with complementary properties: a structural barrier material providing mechanical strength and basic thermal isolation, and a thermal resistance material layer (such as aerogel or mica) providing enhanced thermal resistance. This composite structure achieves effective thermal inhibition without excessive complexity.

Inventive Principle:

Principle #40Composite materials

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 effectively slows or prevents the transfer of thermal energy across the cell stack, thereby reducing the risk of thermal events and enhancing the structural integrity and thermal management of the traction battery pack.

Implementation Method 1

thermal resistance material layer arranged to inhibit the transfer of thermal energy from a first battery cell to a second battery cell

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250193979A1Thermal barrier assemblies with thermal resistance material layers of a non-uniform thickness

Publication Date: 2025.06.12 FORD GLOBAL TECH LLC

AI summary

Thermal barrier assemblies are provided for inhibiting the transfer of thermal energy inside a traction battery pack. An exemplary thermal barrier assembly may include a structural barrier flanked by a pair of thermal resistance material layers. The structural barrier and the thermal resistance material layers may each include a non-uniform thickness. The structural barrier may include a reduced thickness at its respective outboard edges, and the thermal resistance layers may each include an increased thickness at their respective outboard edges. Providing a greater amount of thermal resistance material near the outboard edges of battery cells can help slow or even eliminate the transfer of thermal energy across a cell stack of the traction battery pack during a thermal event.