Battery Housing Composite Layer for Fire and Gas Stream Protection
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Solution Overview
Problem
Existing fire protection solutions for high voltage batteries do not provide adequate mechanical resistance to damage-induced gas and/or flame streams, which can compromise the integrity of the battery housing and destroy thermal insulation layers.
Innovation Solution
A composite layer with a thermally insulating intumescent material and a protective layer, such as a glass fiber fabric, is applied to the interior surface of the battery housing, where the protective layer shields the insulation layer from mechanical stress and prevents destruction by gas and/or flame streams, and a predetermined breakthrough site directs the stream to a safe exit path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermally insulating intumescent material is applied to battery cells, then thermal insulation is improved, but mechanical resistance to gas and flame streams deteriorates
Solution Approach 1:
The patent applies a composite protective structure consisting of an intumescent thermal insulation layer combined with a mechanically robust protective layer (such as aluminum foil, metal mesh, or ceramic coating). This composite structure simultaneously provides thermal insulation through the intumescent material and mechanical resistance to gas and flame streams through the protective layer, resolving the contradiction between thermal protection and mechanical strength.
Solution Approach 2:
The patent implements different material properties at different locations and layers: the inner layer uses intumescent material optimized for thermal insulation and volume expansion upon heating, while the outer layer uses materials specifically selected for mechanical strength and resistance to erosive forces. This local differentiation of material qualities allows each layer to perform its specialized function optimally.
2Strength
If a protective layer is added to enhance mechanical resistance, then mechanical strength is improved, but device complexity increases
Solution Approach 1:
The patent employs thin-film protective layers such as aluminum foil or metal meshes that provide substantial mechanical strength and resistance to gas/flame streams despite their minimal thickness. These thin films maintain structural integrity under pressure while adding minimal complexity to the overall battery cell structure, avoiding the need for bulky protective components.
Solution Approach 2:
The protective layer serves multiple functions simultaneously: it provides mechanical strength, resists erosion from gas and flame streams, maintains structural integrity of the battery housing, and in some implementations (such as aluminum foil), provides additional thermal reflection and barrier properties. This multi-functionality reduces the need for separate components.
3Reliability
If the entire battery housing interior is covered with composite protective layer, then protection is improved, but material usage and cost increase
Solution Approach 1:
The patent strategically positions the composite protective structure at specific high-risk locations where thermal and mechanical hazards are most concentrated, such as around individual battery cells, at thermal insulation interfaces, and in areas most susceptible to gas/flame stream impact. This localized application maintains critical protection while significantly reducing overall material consumption compared to full-surface coverage.
Solution Approach 2:
The protective system is divided into discrete segments or zones corresponding to individual battery cells or critical areas, rather than applying a continuous layer across the entire battery housing interior. This segmentation allows for targeted protection where needed while leaving non-critical areas uncovered, optimizing the balance between protection and material usage.
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 maintains thermal insulation and prevents mechanical destruction of the battery housing by channeling and containing damage-induced gas and/or flame streams, ensuring the integrity of the battery housing and reducing material usage.
Implementation Method 1
a layer which consists at least partially of an intumescent material, that is to say a material which is capable of foaming by exposure to heat
Implementation Method 2
the foamable coating encloses a cell group or a cell stack at least partially or is arranged between individual battery cells as thermally insulating layer
Data Source
AI summary
A battery with a fire protection device, wherein the battery includes a plurality of battery cells and a battery housing, wherein a respective battery cell is arranged in an interior space of the battery housing. The fire protection device includes a composite layer with a thermal insulation layer and with a protective layer arranged on the insulation layer, wherein the composite layer is arranged on a battery housing interior side facing the interior space of the battery housing, and the insulation layer is arranged as an intermediate layer between a surface of the battery housing interior side and the protective layer and is protected by the protective layer against a gas and/or flame stream exiting the respective battery cell in the event of damage, whereby its thermally insulating properties are maintained.