Battery Module Insulation Sheet for Thermal Runaway Containment
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Solution Overview
Problem
High-capacity secondary batteries, such as lithium ion batteries, face issues with thermal runaway, leading to overheating and potential fires, which can spread to adjacent cells due to inadequate thermal insulation and fire resistance in conventional battery modules.
Innovation Solution
A battery module design featuring an insulation sheet with an aerogel layer and a foam layer on its side surfaces, providing enhanced thermal insulation, fire resistance, and flame retardancy by inhibiting heat and flame propagation between cells. The insulation sheet includes a substrate, an aerogel layer with specific surface area and composition, and a foam layer that expands at elevated temperatures to fill empty spaces and prevent flame spread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation sheets are used between cells, then basic thermal insulation is provided, but fire resistance and flame retardancy are insufficient allowing heat propagation
Solution Approach 1:
The patent applies composite materials by combining aerogel layer (providing exceptional thermal insulation with low thermal conductivity) and foam layer (providing fire resistance and flame retardancy) with the substrate to create an insulation sheet that simultaneously achieves both thermal insulation and fire resistance without excessive complexity
Solution Approach 2:
The patent applies local quality by forming the foam layer specifically on the side surface portions of the insulation sheet that face adjacent cells, concentrating the fire-resistant material where heat propagation risk is highest, while maintaining a simpler structure in other areas
2Temperature
If aerogel layer is added to insulation sheet, then thermal insulation is improved, but aerogel detachment and contamination may occur
Solution Approach 1:
The patent applies flexible shells and thin films by using a substrate (such as a flexible polymer film) as the base layer of the insulation sheet, which provides mechanical support and prevents aerogel detachment while maintaining thermal insulation performance, thereby ensuring aerogel stability
Solution Approach 2:
The patent applies composite materials by creating a multi-layer structure where the aerogel layer is combined with the substrate and foam layer, forming a composite material system where each component reinforces the others to prevent aerogel detachment and contamination
3Object-affected harmful factors
If foam layer is formed on insulation sheet, then flame propagation is prevented, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by forming the foam layer selectively only on the side surface portions of the insulation sheet that face adjacent cells, rather than covering the entire surface, thereby preventing flame propagation in critical areas while reducing manufacturing complexity and material usage
4Use of energy by moving object
If high-capacity cells are used, then energy density is improved, but thermal runaway risk increases affecting adjacent cells
Solution Approach 1:
The patent applies intermediary (Mediator) by introducing the insulation sheet with aerogel layer and foam layer as intermediary barriers between high-capacity cells, which mediate the thermal interaction by absorbing and blocking heat transfer, thereby allowing high energy density while preventing harmful heat propagation during thermal runaway
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 or prevents heat and flame propagation between cells during thermal runaway, enhancing safety by providing improved thermal insulation, mechanical strength, and dimensional stability, while minimizing the risk of aerogel detachment and contamination.
Implementation Method 1
an aerogel layer between the first substrate and the second substrate
Implementation Method 2
a foam layer that expands at elevated temperatures to fill empty spaces and prevent flame spread
Data Source
AI summary
Example embodiments include a battery module including a plurality of cells, an insulation sheet between the plurality of cells, the insulation sheet having an upper surface and a lower surface that face cells adjacent thereto, respectively, and a foam layer formed on two or more side surface portions, including an upper side surface portion, of a border side surface between the upper surface and the lower surface of the insulation sheet. Example embodiments also include a method of manufacturing the battery module, and a battery pack including the battery module.