Battery Module Housing With Conductive Polymer for Thermal Propagation Delay
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Secondary batteries are prone to thermal runaway and thermal propagation due to heat, gas, or flames generated by one battery cell transferring to adjacent cells, which can cause damage and safety issues.
Innovation Solution
A battery module design incorporating a thermal transfer blocking assembly with a heat insulating member and buffer member, a module housing with slits, and a thermally conductive polymer in the slits, where the polymer's melting point is lower than the housing material, to delay heat transfer and prevent thermal propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a module housing with high thermal conductivity is used to dissipate heat from battery cells, then heat dissipation performance is improved, but thermal propagation risk increases
Solution Approach 1:
The module housing is segmented into different thermal conductivity zones: high thermal conductivity materials are used in areas requiring heat dissipation, while low thermal conductivity materials are used in areas requiring thermal isolation. This segmentation allows simultaneous heat dissipation and thermal propagation prevention.
Solution Approach 2:
Different portions of the module housing have different thermal properties tailored to their specific functions. The housing structure incorporates regions with high thermal conductivity for heat dissipation and regions with low thermal conductivity for thermal barrier functions, optimizing both heat management and safety.
2Object-affected harmful factors
If thermal transfer blocking assemblies are added between battery cells, then thermal propagation prevention is improved, but device complexity increases
Solution Approach 1:
The thermal transfer blocking assembly is merged with the module housing structure, combining the housing's structural support function with the thermal barrier function. This integration reduces the number of separate components and simplifies the overall device structure.
Solution Approach 2:
The module housing serves multiple functions: it provides structural support, facilitates heat dissipation through high thermal conductivity regions, and prevents thermal propagation through low thermal conductivity regions. This multi-functionality eliminates the need for separate dedicated components for each function.
3Object-affected harmful factors
If slits are formed in the main plate to accommodate thermally conductive polymer, then thermal transfer blocking is improved, but manufacturing precision requirements increase
Solution Approach 1:
The thermally conductive polymer undergoes a phase change from solid to liquid when exposed to heat, allowing it to flow into the slits and conform to the required geometry. This eliminates the need for precise slit formation, as the polymer self-adjusts to fill the space.
Solution Approach 2:
The slits are pre-formed in the main plate at locations where thermal blocking is needed, but the final thermal barrier structure is completed by the polymer's phase change and flow into the slits during operation or assembly, rather than requiring precise pre-forming of the complete barrier structure.
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 design effectively reduces heat transfer between battery cells, delaying thermal propagation and maintaining cell temperatures within safe limits, thereby enhancing safety and preventing damage.
Implementation Method 1
a thermally conductive polymer disposed in the at least one slit
Implementation Method 2
a melting point of the thermally conductive polymer may be lower than a melting point of the main plate
Implementation Method 3
the at least one thermal transfer blocking assembly may include a heat insulating member
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Battery modules and battery packs are disclosed. In an embodiment of the disclosed technology, a battery module may include a cell assembly including a plurality of battery cells and at least one thermal transfer blocking assembly interposed between two or more adjacent battery cells of the plurality of battery cells; a module housing including a main plate structured to support the cell assembly; at least one slit formed in the main plate and arranged to face the at least one thermal transfer blocking assembly; and a thermally conductive polymer disposed in the at least one slit. A melting point of the thermally conductive polymer may be lower than a melting point of the main plate.