Multilayer Battery Insulation Structure for Thermal Runaway Barriers
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Solution Overview
Problem
The challenge in the automotive industry is to develop a thermal management solution for electric vehicle batteries that effectively mitigates the risk of thermal runaway and mechanical damage due to high energy density and rapid heat generation, while also allowing for the expansion and contraction of battery cells without compromising thermal insulation properties.
Innovation Solution
A multilayer construction comprising a polymeric foam layer and a spacer layer with protruding portions, where at least one terminal portion of each spacer element is fully embedded into the polymeric foam layer, providing excellent thermal insulation, compressibility, and resistance to high compression forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal management solutions are implemented to mitigate temperature rise in battery assemblies, then thermal insulation performance is improved, but device complexity increases
Solution Approach 1:
The patent employs a composite multilayer construction comprising a polymeric foam layer and a spacer layer with protruding portions. The polymeric foam layer provides thermal insulation while the spacer layer maintains structural integrity and allows for cell expansion. This composite structure achieves effective thermal management without requiring complex active cooling systems, thereby improving thermal insulation performance while controlling device complexity.
2Quantity of substance
If high energy density battery cells are used to cover longer distances, then energy storage capacity is improved, but the risk of thermal runaway events increases
Solution Approach 1:
The patent segments the battery assembly into individual battery cells separated by spacer layers. Each cell is independently supported and insulated, preventing thermal runaway propagation to neighboring cells. The spacer layer acts as a physical barrier that compartmentalizes the energy storage system, allowing high energy density cells to be used while mitigating the harmful effects of thermal runaway through spatial separation.
3Power
If battery cells are designed for fast charging and discharging cycles, then power delivery is improved, but mechanical damage risk increases due to expansion and contraction
Solution Approach 1:
The patent incorporates a spacer layer with protruding portions that dynamically adapt to battery cell expansion and contraction during charging and discharging cycles. The spacer elements can flex and adjust their position, maintaining consistent support and spacing while accommodating the mechanical changes. This dynamic design preserves the structural integrity and mechanical durability of the battery assembly even during fast charging cycles that induce significant expansion and contraction.
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 offers outstanding thermal insulation, thermal runaway barrier performance, and compressibility, maintaining foam structure under high-pressure conditions, and is suitable for thermal management in the transportation industry, particularly in battery modules, with enhanced durability and safety features.
Implementation Method 1
A multilayer construction comprising a polymeric foam layer; and at least one spacer layer comprising a plurality of spacer elements... providing excellent thermal insulation
Implementation Method 2
at least one terminal portion of each spacer element is fully embedded into the polymeric foam layer... resistance to high compression forces
Data Source
AI summary
The present disclosure relates to a multilayer construction comprising a polymeric foam layer; and at least one spacer layer comprising a plurality of spacer elements, wherein each spacer element comprises a protruding portion and two opposite terminal portions, and wherein at least one terminal portion of each spacer element is fully embedded into the polymeric foam layer.