Battery Module Insulation Sheet with Phase Change Material
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Solution Overview
Problem
Battery modules in electric vehicles face heat insulation challenges due to increased spacing between cells to prevent swelling, which can lead to deteriorated heat-insulating performance and module size issues, potentially causing heat-related failures.
Innovation Solution
Incorporating phase change materials within insulation sheets between battery cells, surrounded by protective films, to absorb heat and reduce thermal conductivity, thereby delaying or preventing heat-induced failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the spaced interval between battery cells is increased to prevent swelling, then the safety risk of battery swelling is reduced, but the heat-insulating performance deteriorates and the module size excessively increases
Solution Approach 1:
The insulation sheet is designed with through-holes filled with phase change material at specific locations between battery cells, creating localized thermal management zones rather than uniform insulation throughout. This allows targeted heat absorption where needed while maintaining overall structural integrity and minimizing size increase
Solution Approach 2:
Phase change material is incorporated into the insulation sheet to absorb excess heat through phase transition (melting) when battery temperature rises. This material changes from solid to liquid state at specific temperatures, absorbing large amounts of heat energy and preventing heat accumulation without requiring increased spacing between cells
2Reliability
If the spaced interval between battery cells is increased to prevent swelling, then the safety risk of battery swelling is reduced, but the module size excessively increases
Solution Approach 1:
Rather than uniformly increasing the spacing between all battery cells, the insulation sheet with phase change material is strategically placed only at critical locations where heat accumulation and swelling risks are highest. This localized approach prevents swelling effectively while minimizing the overall volume increase of the battery module
Solution Approach 2:
The insulation sheet is designed as a composite structure combining base insulation material with phase change material-filled through-holes. This composite design provides both mechanical support and thermal management functions within a compact structure, preventing the need for excessive spacing increases
3Object-generated harmful factors
If spacing between battery cells is increased, then heat transfer between cells is reduced, but heat-insulating performance deteriorates due to structural changes
Solution Approach 1:
The insulation sheet acts as an intermediary layer between battery cells, with phase change material serving as a thermal buffer. When heat accumulates, the phase change material absorbs excess thermal energy through phase transition, mediating the thermal interaction between adjacent cells and preventing harmful heat transfer while maintaining proper thermal insulation performance
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 effectively reduces thermal conductivity and prevents heat transfer between battery cells, delaying or reducing the risk of heat-related failures, while maintaining the structural integrity and size of the battery module.
Implementation Method 1
a phase change material filled in the plurality of through holes
Implementation Method 2
absorb heat through a phase change material provided in an insulation sheet
Implementation Method 3
reduces thermal conductivity to prevent or reduce heat transfer between battery cells
Data Source
Figure 1A
Figure 1B
Figure 2~3A
AI summary
A battery module includes a phase change material in an insulation sheet to absorb heat and reduce thermal conductivity, thereby preventing or reducing heat transfer between battery cells, and delaying, preventing, or reducing an event that may be caused by the heat. As an example, the battery module includes a plurality of battery cells and a plurality of insulation sheets interposed between the plurality of battery cells, where each of the insulation sheets includes a heat-insulating sheet having a first surface and second surface, a plurality of through-holes defined in the heat-insulating sheet and passing between the first surface and the second surface opposite the first surface, and a phase change material filled in the plurality of through-holes.