Three-Layer Battery Pack Holder for Thermal Runaway Containment
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Solution Overview
Problem
Battery packs with multiple cells connected in series or parallel face challenges in preventing thermal runaway, as existing insulation methods fail to effectively contain heat when the holder melts due to abnormal heat generation, potentially causing adjacent cells to burn.
Innovation Solution
A battery pack design featuring a three-layer structure partition wall with a thermally insulating plate inside and resin molded layers on both sides, which remains intact even when one side melts, preventing heat transfer and protecting adjacent cells from thermal runaway, and includes inflow spaces to efficiently cool and isolate heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a plastic holder is used to arrange battery cells at fixed positions, then the battery cells can be arranged at fixed positions, but the holder would melt under abnormal heat and fail to partition adjacent battery cells
Solution Approach 1:
The partition wall is constructed as a composite structure with three layers: a heat-resistant plate (mica or ceramic) in the middle layer, and heat-resistant resin layers on both sides. This composite structure combines the heat resistance of inorganic materials with the molding advantages of plastics, enabling the holder to maintain structural integrity and thermal insulation capability even under abnormal heat conditions while still allowing easy arrangement of battery cells at fixed positions
Solution Approach 2:
The invention changes the thermal parameters of the holder material by incorporating heat-resistant plates with high melting points (mica: 950-1000°C, ceramic: 2000-3000°C) into the resin structure. This parameter change enables the holder to withstand abnormal heat temperatures that would normally cause standard plastic holders to melt, thereby maintaining the partitioning function and preventing thermal runaway propagation
2Reliability
If a mica plate is disposed between adjacent battery cells to insulate heat, then thermal insulation is improved, but the holder cannot be mass-produced as a single-piece plastic structure
Solution Approach 1:
The invention merges the heat-resistant plate (mica or ceramic) with the resin holder into a single integrated partition wall structure. The heat-resistant plate is positioned in the middle layer with resin layers on both sides, forming a unified component that can be molded as a single piece. This merging maintains the thermal insulation benefits of the mica plate while enabling mass production through single-piece molding, eliminating the need for separate assembly steps
Solution Approach 2:
The partition wall uses a composite material structure where heat-resistant plates (mica or ceramic) are embedded within heat-resistant resin layers. This composite construction allows the entire partition wall to be molded as a single piece while maintaining the thermal insulation properties of the inorganic plate material, thus achieving both reliable thermal insulation and ease of mass production
3Weight of moving object
If battery cells are arranged without gap to decrease size and weight, then portability is improved, but thermal runaway can propagate to adjacent cells more easily
Solution Approach 1:
The partition wall is constructed as a composite structure with a heat-resistant plate (mica or ceramic) in the middle layer and heat-resistant resin layers on both sides. This composite structure provides superior thermal insulation compared to standard plastic holders, creating an effective thermal barrier between adjacent battery cells. The heat-resistant plate has high melting point and low thermal conductivity, preventing heat transfer even when battery cells are arranged without gaps, thus stopping thermal runaway propagation while maintaining compact battery pack design
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
Effectively prevents thermal runaway by maintaining structural integrity and insulation, even when heated, and allows for mass production as a single-piece plastic structure, ensuring the battery pack's safety and reliability.
Implementation Method 1
Partition wall 23 has a three-layer structure that thermally insulating plate 13 is disposed inside and resin molded layer 12 is laminated on both surfaces of thermally insulating plate 13
Implementation Method 2
the plastic of the resin molded layer in contact with the battery pack having generated abnormal heat would melt but the plastic of the resin molded layer on the opposite side would not melt in the presence of the thermally insulating plate
Implementation Method 3
the resin molded layer laminated on one surface of the thermally insulating plate will thermally melt with the battery cell having generated abnormal heat and absorbs the heat of melting
Data Source
AI summary
A battery pack includes a plurality of battery cells and holder that has battery cells arranged in a parallel posture. Holder has partition wall between adjacent battery cells for arranging battery cells at fixed positions. Partition wall has a surface facing battery cells as resin molded layer shaped to arrange battery cells at the fixed positions. Partition wall has a three-layer structure where thermally insulating plate is disposed inside and resin molded layer is laminated on both surfaces of thermally insulating plate. Holder is formed in a single-piece structure by molding resin molded layer from a synthetic resin.