Laminated Battery Pack Insulator With Air Pockets for Flame Blocking
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Solution Overview
Problem
Conventional thermal and dielectric insulators, such as fiberglass fabric, fail to effectively inhibit flame propagation within and from electric vehicle battery packs, particularly during thermal runaway conditions, and do not provide adequate dielectric protection, while also being bulky and heavy.
Innovation Solution
A flexible thermal insulator with a laminated structure comprising heat-resistant outer layers, an intermediate fabric layer, and compressible spacers forming air pockets, which provides dielectric protection and inhibits flame propagation for extended periods at high temperatures, while being lightweight and compact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If fiberglass fabric insulation is used, then thermal insulation is provided, but flame propagation protection is insufficient
Solution Approach 1:
The patent employs a composite insulation structure consisting of multiple layers including fiberglass fabric, heat-resistant coating layers, and air pockets. This composite approach combines the thermal insulation properties of fiberglass with the flame resistance of heat-resistant coatings and the thermal barrier effect of air pockets, achieving both thermal insulation and flame propagation protection simultaneously
Solution Approach 2:
The patent introduces air pockets as intermediary thermal barriers between the battery cells and the external environment. These air pockets act as mediators that provide additional thermal resistance and flame propagation delay without directly contacting the battery cells, enhancing protection while maintaining a compact structure
2Object-affected harmful factors
If conventional thermal insulation is used, then thermal protection is provided, but dielectric protection is insufficient
Solution Approach 1:
The heat-resistant coating layers in the composite structure provide both thermal and dielectric protection properties. These coatings are specifically designed to resist high temperatures while also providing electrical insulation, thereby simultaneously addressing both thermal and dielectric protection requirements
3Object-affected harmful factors
If fiberglass fabric insulation is used, then thermal insulation is provided, but weight increases
Solution Approach 1:
The patent uses thin film heat-resistant coatings applied to the fiberglass fabric structure. These thin coatings provide effective thermal and flame protection while adding minimal weight compared to using thick layers of bulk insulation material
Solution Approach 2:
The patent incorporates air pockets within the insulation structure, utilizing air as a lightweight thermal barrier. This pneumatic approach provides effective thermal insulation with minimal mass, as air has extremely low density compared to solid insulation materials
4Object-affected harmful factors
If conventional insulation is used, then thermal protection is provided, but tolerance stack-up issues occur
Solution Approach 1:
The flexible nature of the thin film heat-resistant coatings allows them to conform to slight variations in battery cell dimensions and positioning. This flexibility accommodates manufacturing tolerances and assembly variations without compromising the thermal protection effectiveness or requiring extremely tight tolerance control
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 flexible thermal insulator effectively suppresses flame propagation between battery cells for up to 10 minutes at 1000°C, offers dielectric protection, minimizes weight and space, and simplifies assembly by relaxing stack-up tolerances, making it suitable for electric vehicle battery packs.
Implementation Method 1
a first air pocket between the first laminated outer layer and the intermediate layer. A second spacer is sandwiched between the second laminated outer layer and the intermediate layer. The inner second spacer periphery bounds a space forming a second air pocket between the second laminated outer layer and the intermediate layer
Data Source
AI summary
A flexible thermal insulator for an electric vehicle battery pack includes a first laminated outer layer bounded by a first outer layer periphery and a second laminated outer layer bounded by a second outer layer periphery. The first and second laminated outer layers each include respective first and second outer heat-resistant layers bonded to respective first and second heat-resistant outer coatings. An intermediate layer is sandwiched between the first laminated outer layer and the second laminated outer layer. A first circumferentially continuous, annular spacer is sandwiched between the first laminated outer layer and the intermediate layer to define and bound a first air pocket between the first laminated outer layer and the intermediate layer. A second circumferentially continuous, annular spacer is sandwiched between the second laminated outer layer and the intermediate layer to define and bound a second air pocket between the second laminated outer layer and the intermediate layer.