Thermal Barrier Shield Structure for Battery Pack Heat Containment
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Solution Overview
Problem
Traction battery packs in electrified vehicles face challenges in managing thermal energy, particularly during battery thermal events, which can lead to the transfer of heat from battery cells to the enclosure cover, potentially compromising the structural integrity and performance of the battery pack.
Innovation Solution
The implementation of a thermal barrier shield supported by structural thermal barrier assemblies, which include thermal barrier fins made of polymer composite structures with aerogel and foam layers, and an upper interfacing structure with a basin for adhesive reception, effectively inhibits the transfer of thermal energy from the cell packet to the enclosure cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If thermal barrier shield and structural thermal barrier assemblies are added to prevent heat transfer, then thermal protection of enclosure cover is improved, but device complexity increases
Solution Approach 1:
The thermal barrier shield is integrated within the existing battery pack structure, nested between the cell stack and enclosure cover. The structural thermal barrier assemblies are positioned at interfaces within the enclosure assembly, creating a nested configuration that provides thermal protection without requiring a completely separate external system.
Solution Approach 2:
The structural thermal barrier assemblies utilize composite material construction, combining materials with different thermal properties to achieve both structural support and thermal barrier functions. This allows a single component to serve multiple purposes, reducing overall system complexity despite adding thermal protection capabilities.
2Temperature
If multiple thermal barrier components are implemented, then thermal energy management is improved, but manufacturing complexity increases
Solution Approach 1:
The thermal barrier system is divided into discrete, modular components including the thermal barrier shield and multiple structural thermal barrier assemblies. Each component can be manufactured independently using standardized processes, and the segmentation allows for specialized manufacturing techniques optimized for each component's specific requirements.
Solution Approach 2:
The structural thermal barrier assemblies include pre-formed upper interfacing structures with basins designed to receive adhesives during assembly. This preliminary preparation of bonding surfaces and alignment features simplifies the manufacturing and assembly process by ensuring proper positioning and bonding conditions are already established before final assembly operations.
3Object-affected harmful factors
If thermal barrier fin with multi-layer structure is used, then thermal insulation performance is improved, but weight of battery pack increases
Solution Approach 1:
The thermal barrier fin incorporates a multi-layer structure that includes porous material layers. Porous materials provide effective thermal insulation through trapped air pockets and reduced thermal conductivity, achieving high insulation performance with relatively low material density and weight compared to solid non-porous alternatives.
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 solution effectively manages thermal energy within the traction battery pack, preventing heat transfer during battery thermal events and maintaining the structural integrity and performance of the battery pack.
Implementation Method 1
a thermal barrier shield supported at a position between the enclosure cover and the cell packet by the first structural thermal barrier assembly and the second structural thermal barrier assembly
Implementation Method 2
the thermal barrier fin includes a polymer composite structure
Implementation Method 3
The thermal barrier fin is flanked by aerogel layers and foam layers to establish a multi-layer sandwich structure
Implementation Method 4
The thermal barrier fin is flanked by aerogel layers and foam layers to establish a multi-layer sandwich structure
Implementation Method 5
the polymer composite structure includes a glass fiber reinforced polypropylene with an intumescent additive
Data Source
AI summary
Thermal barrier shields are provided for traction battery packs. The thermal barrier shield may be arranged to inhibit the transfer of thermal energy from a cell packet of a cell stack to an enclosure cover of the traction battery pack. The cell packet may be arranged between a first structural thermal barrier assembly and a second structural thermal barrier assembly of the cell stack. The thermal barrier shield may be supported at a position between the enclosure cover and the cell packet by the first structural thermal barrier assembly and the second structural thermal barrier assembly.