Battery Module Metal Sheet Thermal Barrier Design
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Solution Overview
Problem
Battery modules face issues with thermal runaway propagation due to inadequate heat dissipation, leading to potential fires or explosions, as the module frame melts at high temperatures, compromising the structure and safety of the battery pack.
Innovation Solution
Incorporating a metal sheet with a melting point higher than the module frame, positioned between the battery cell stack and the module frame, along with an insulating coating or film, to prevent heat propagation and structural collapse, and optionally integrating it with a busbar frame or using a thermal conductive resin layer for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of battery cells are stacked to obtain high output, then power density is improved, but heat dissipation becomes difficult and temperature rises excessively
Solution Approach 1:
The battery module is divided into multiple battery cell stacks arranged in parallel. Each stack is an independent unit that can dissipate heat separately, preventing heat accumulation in a single concentrated location while maintaining high overall output capacity.
Solution Approach 2:
A heat dissipation plate is introduced as an intermediary component between the battery cells and the module frame. This plate conducts heat away from the battery cells and distributes it to the module frame, facilitating efficient heat transfer and dissipation while allowing continued high-power operation.
2Weight of moving object
If the module frame is made of aluminum material for lightweight construction, then weight is reduced, but the frame melts at temperatures of 300°C or more causing structural collapse
Solution Approach 1:
The module frame is constructed using composite material comprising both aluminum and magnesium elements. This composite structure combines the lightweight advantage of aluminum with the high-temperature resistance of magnesium alloys, maintaining structural integrity at temperatures exceeding 300°C while keeping the overall weight low.
Solution Approach 2:
The material composition parameters of the frame are changed by incorporating magnesium elements alongside aluminum. This parameter modification raises the melting point and thermal stability of the frame material, enabling it to withstand thermal runaway temperatures without structural collapse.
3Quantity of substance
If battery cells are closely arranged to increase energy density, then space utilization is improved, but heat dissipation becomes more difficult
Solution Approach 1:
Heat dissipation plates are positioned between the closely arranged battery cell stacks to act as thermal conduits. These plates maintain close spacing for high energy density while simultaneously providing dedicated heat transfer pathways, allowing heat to be efficiently conducted away from the cells despite their close arrangement.
Solution Approach 2:
The module structure implements local heat dissipation channels between individual battery stacks. This local quality approach allows heat to be managed at each stack level rather than relying on global dissipation, enabling close cell arrangement while maintaining effective heat removal at critical locations.
4Ease of manufacture
If the module frame structure is simplified for ease of manufacture, then manufacturing complexity is reduced, but the ability to prevent thermal runaway propagation is compromised
Solution Approach 1:
The module frame is designed with multi-functionality, serving both as the structural support element and as an integrated heat dissipation system. By incorporating heat dissipation plates and thermal management features directly into the frame structure, the design prevents thermal runaway propagation without adding separate complex safety systems, maintaining manufacturing simplicity while enhancing reliability.
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 metal sheet effectively suppresses thermal runaway propagation between battery modules, improving the stability and safety of the battery module by preventing heat transfer and maintaining the structural integrity even if the module frame melts, thereby reducing the risk of fire or explosion.
Implementation Method 1
a metal sheet positioned between the battery cell stack and the module frame... to prevent heat propagation and structural collapse
Implementation Method 2
optionally integrating it with a busbar frame or using a thermal conductive resin layer for enhanced stability
Data Source
AI summary
A battery module includes a battery cell stack in which a plurality of battery cells are stacked; a module frame for housing the battery cell stack; and a metal sheet positioned between the battery cell stack and the module frame.