Battery Module Flame Barrier for Thermal Runaway Isolation
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Solution Overview
Problem
Conventional methods for preventing flame spread and ensuring safety in battery modules, such as using thermally conductive additives or fire-resistant materials, either fail to suppress thermal runaway or compromise energy density and stability due to dust generation, short circuits, and high density.
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, along with an inorganic filler, which prevents short circuits and effectively suppresses heat and flame spread by minimizing dust generation and maintaining structural integrity.
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
Solution Approach 1:
The patent uses a composite material consisting of heat-resistant fibers (such as glass fibers or ceramic fibers) embedded in a binder resin matrix. This composite structure combines the flame resistance of inorganic fibers with the cohesive properties of the resin, preventing dust generation while maintaining fire suppression capabilities.
Solution Approach 2:
The flame-retardant material is formed as a flexible sheet or mat structure that can be layered between battery cells. This thin film form factor prevents dust generation compared to loose materials like ceramic wool, while still providing effective flame barrier properties.
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 adhesive thickness must be increased reducing energy density
Solution Approach 1:
The composite material with binder resin provides sufficient adhesive strength and structural integrity, allowing thin-layer application between battery cells. This eliminates the need for thick adhesive layers that would reduce energy density, while maintaining flame retardant performance.
3Temperature
If thermally conductive additives are used for cooling, then heat generated during battery operation is cooled, but thermal runaway situations are not suppressed
Solution Approach 1:
The patent applies different material properties to different functions: thermally conductive additives are used for operational cooling, while heat-resistant fibrous composite materials are specifically deployed at interfaces between battery cells to suppress flame spread and thermal runaway. This localized quality differentiation resolves the contradiction between cooling and fire suppression.
Solution Approach 2:
The heat-resistant fibrous composite material acts as an intermediary barrier layer between battery cells. It does not interfere with operational cooling through thermally conductive additives, but provides a physical barrier that suppresses flame spread and thermal runaway propagation.
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 achieves both weight reduction and improved flame retardancy, preventing short circuits and thermal runaway while maintaining high energy density and stability, as demonstrated by effective insulation and durability in high-temperature environments.
Implementation Method 1
an inorganic long fiber network which suppresses spread of heat or flame when ignition occurs
Implementation Method 2
the inorganic filler may include one or two selected from an endothermic material and a thermally expandable material
Implementation Method 3
the inorganic filler may include one or two selected from an endothermic material and a thermally expandable material
Data Source
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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.