Multi-Layer Battery Insulation for Thermal Stability
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Solution Overview
Problem
Electric vehicle batteries experience significant temperature fluctuations, leading to reduced lifespan and increased energy consumption for active temperature control systems, which affects vehicle range.
Innovation Solution
A multi-layer insulation structure comprising a metallic facing layer and nonwoven layers with high temperature resistance, including inorganic and organic fibers, is used to reduce temperature fluctuations and maintain battery temperature within a stable range, thereby reducing the energy required for active temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If active temperature control systems are used to regulate battery temperature, then battery temperature stability is improved, but energy consumption increases
Solution Approach 1:
The patent applies preliminary action by installing a multi-layer insulation system in advance within the battery pack structure. This insulation system proactively prevents heat transfer before temperature extremes occur, reducing the workload on active temperature control systems and thereby lowering energy consumption while maintaining temperature stability.
Solution Approach 2:
The patent uses composite materials by combining multiple insulation layers with different properties (including thermal insulation layers and metallic facing layers) to create a comprehensive thermal management system. This composite structure provides both passive insulation and active temperature control capabilities, improving temperature stability while reducing energy consumption compared to active systems alone.
2Duration of action of stationary object
If multi-layer insulation structure is added to reduce temperature fluctuations, then battery life cycle is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the insulation system into multiple distinct layers, each with specific functions. The multi-layer structure includes thermal insulation layers for heat resistance and metallic facing layers for radiant heat reflection. This segmentation allows each layer to be optimized independently while working together to protect the battery, extending battery life cycle without creating unmanageable complexity.
Solution Approach 2:
The patent employs composite materials by integrating different material types (thermal insulation materials and metallic facing materials) into a unified multi-layer system. This composite approach provides comprehensive thermal protection that extends battery life while maintaining manageable system complexity through standardized layer configurations.
3Stability of the object's composition
If insulation layers are added to maintain battery temperature, then temperature fluctuation amplitude is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by designing the insulation system as separate, modular layers that can be manufactured independently and then assembled. The thermal insulation layers and metallic facing layers are produced as discrete components, allowing for specialized manufacturing processes for each layer type while simplifying the overall assembly process. This segmentation reduces manufacturing complexity compared to creating a single integrated insulation system.
Solution Approach 2:
The patent uses flexible shells and thin films by employing thin metallic facing layers and flexible thermal insulation materials that can be easily conforming to the battery pack geometry. These flexible components are simple to manufacture and install, reducing manufacturing complexity while effectively reducing temperature fluctuation amplitude through their thermal management properties.
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 multi-layer insulation structure effectively maintains battery temperature, enhances battery life cycle, and minimizes the negative impact on vehicle range by reducing energy consumption for temperature regulation.
Implementation Method 1
The multi-layer structure may include a metallic facing layer... The metallic facing may be an aluminum foil... The aluminum foil may be a reinforced aluminum foil
Implementation Method 2
Each nonwoven layer may have a temperature resistance of about 400° C. or greater... One or more of the nonwoven layers may include inorganic fibers... One or more of the nonwoven layers may include organic fibers
Data Source
AI summary
An insulation material having three or more layers, the layers including a metallic facing; and one or more nonwoven layers. One or more of the layers may be a needle punched layer. Each nonwoven layer may have a temperature resistance of about 400° C. or greater. The insulation material may be used for surrounding and insulating a battery, such as a battery for an electric vehicle.