Battery Cell Assembly Using Insulating Particles to Block Heat Spread
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Solution Overview
Problem
Secondary batteries face stability issues due to heat or gas generation, which can accelerate heat propagation and affect adjacent cells, leading to potential safety hazards.
Innovation Solution
A battery assembly design incorporating particle-shaped insulating materials with specific hardness and electrical/thermal properties, distributed within the case to enhance stability, thermal insulation, and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are densely packed to increase energy density, then productivity and space utilization improve, but heat propagation accelerates and stability deteriorates
Solution Approach 1:
Particle-shaped insulating materials are introduced as intermediary substances filled in the gaps between battery cells. These particles act as thermal barriers that slow down heat propagation while maintaining compact cell arrangement, thus resolving the contradiction between high energy density and thermal stability.
Solution Approach 2:
The use of particle-shaped insulating materials creates a porous structure between battery cells. This porous arrangement provides thermal insulation pathways that hinder heat transfer while allowing the battery assembly to maintain high cell density, addressing both productivity and reliability requirements.
2Strength
If insulating materials with high hardness are used to prevent damage, then strength improves, but the materials may damage battery cell exterior materials
Solution Approach 1:
The hardness parameter of insulating materials is optimized to a specific range (Shore A5-A95) that balances protective function and compatibility. This parameter optimization ensures the insulating particles are hard enough to resist vibration damage while soft enough to avoid damaging battery cell exterior materials.
Solution Approach 2:
The insulating particles exhibit local quality adaptation where their hardness is sufficient to provide structural support and vibration resistance in the gaps between cells, yet remains compatible with the softer exterior materials of battery cells. This localized property distribution resolves the contradiction between strength and harm prevention.
3Ease of manufacture
If particle-shaped insulating materials are used instead of solid insulation blocks, then ease of manufacture improves, but filling ratio control becomes more difficult
Solution Approach 1:
The filling ratio of particle-shaped insulating materials is controlled within a specific range (30-70%) to optimize both ease of manufacture and manufacturing precision. This parameter control ensures sufficient insulation while avoiding excessive complexity in the filling process, balancing manufacturability with precision requirements.
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 design improves the stability, thermal insulation, and electrical insulation of battery assemblies, preventing heat and gas propagation, thereby enhancing safety and efficiency.
Implementation Method 1
a plurality of particle-shaped insulating materials accommodated in a second inner space of the case
Implementation Method 2
a plurality of particle-shaped insulating materials accommodated in a second inner space of the case
Data Source
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AI summary
A battery assembly which comprises a case (30), a plurality of battery cells (10) accommodated in a first inner space of the case, and a plurality of particle-shaped insulating materials (80) accommodated in a second inner space of the case.