Battery Module Elastic Refractory Layer for Nail Penetration Safety
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Solution Overview
Problem
High-voltage battery modules face ignition risks due to internal short circuits caused by nail penetration, which existing technologies have not effectively prevented or delayed.
Innovation Solution
A battery module incorporating an elastic refractory material with an elastic layer and a heat conductive layer, applied between the outer case and cells, that expands to enclose penetrating nails and dissipates heat to prevent short circuits and ignition, comprising materials like silicone and graphite with specific thermal conductivity and thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a thin film container with thickness of about 0.15 mm is used to increase energy density, then the energy density of the battery is improved, but the resistance to nail penetration and short circuit prevention deteriorates
Solution Approach 1:
An elastic refractory material is introduced as an intermediary layer between the thin film container and the penetrating nail. This material serves as a mediator that prevents direct contact between the nail and the cell, thereby maintaining both the thin film design for high energy density and the protection against short circuits.
Solution Approach 2:
The elastic refractory material combines elastic properties (to deform and wrap around the nail) and refractory properties (to resist heat and maintain structural integrity at high temperatures). This composite material structure allows it to effectively prevent short circuits while working with the thin film container.
2Reliability
If an elastic refractory material is added between the outer case and cells to prevent short circuits, then the short circuit prevention is improved, but the device complexity increases
Solution Approach 1:
The elastic refractory material is designed as a thin film structure that can be easily integrated into the existing battery module architecture. Its flexible nature allows it to conform to the cell surfaces and outer case without requiring complex structural modifications, thereby minimizing the increase in device complexity.
Solution Approach 2:
The elastic refractory material can be divided into multiple segments or layers (including an elastic layer and a heat conductive layer) that can be independently manufactured and then assembled. This segmentation simplifies the manufacturing process and reduces the complexity of integrating a single complex component.
3Reliability
If the elastic layer has high elongation rate of 50% or higher to effectively enclose penetrating nails, then the short circuit prevention is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The material selection focuses on achieving the required elongation rate of 50% or higher through material composition and formulation rather than through complex geometric design. By optimizing the material parameters (such as polymer composition, cross-linking density, and additives), the desired elastic properties are achieved without requiring precise control of geometric dimensions during manufacturing.
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
Effectively prevents and delays internal short circuits and ignition by acting as a separator and heat transfer path, ensuring the stability and safety of high-voltage battery modules.
Implementation Method 1
an elastic refractory material provided in a region between the outer case of the battery module and an outermost cell of the cell assembly or a region between one of the cells and an adjacent cell in the battery module, wherein the elastic refractory material includes an elastic layer and a heat conductive layer
Implementation Method 2
the heat conductive layer may have a thermal conductivity of 0.5 to 500 W/m·K
Data Source
AI summary
A battery module which may prevent or delay a short circuit with respect to nail penetration includes a cell assembly including a plurality of cells electrically connected to each other, an outer case of the battery module, covering the cell assembly, and an elastic refractory material provided in a region between the outer case of the battery module and an outermost cell of the cell assembly or a region between one of the cells and an adjacent cell in the battery module, wherein the elastic refractory material includes an elastic layer and a heat conductive layer.