Battery Pack Exterior Laminate for Early Thermal Runaway Suppression

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Solution Overview

Problem

Lithium-ion batteries in electric vehicles are prone to thermal runaway, leading to high-temperature fires and toxic gas emissions, making it difficult to extinguish and control such fires, which poses a safety risk for passengers and drivers.

Innovation Solution

A self-extinguishable exterior material for battery modules and packs is developed, comprising a metal layer made of aluminum or aluminum alloy, a fire extinguishing agent layer with solid agents like expanded vermiculite, and a resin layer, which are laminated to prevent fire spread and provide a mechanism for early fire suppression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a battery exterior material is designed to provide basic molding and protection functions, then structural integrity and mechanical strength are maintained, but fire safety and automatic extinguishment capability are insufficient

Engineering Contradiction:

Improvefire safetyVSAvoidmaterial structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining metal layers (aluminum or aluminum alloy) with fire extinguishing agent layers containing solid fire extinguishing agents for metal fires. This composite structure integrates both mechanical protection functions and fire safety functions into a single exterior material system, resolving the contradiction between maintaining structural integrity and improving fire safety without significantly increasing device complexity.

Inventive Principle:

Principle #40Composite materials

2Strength

If the metal layer thickness is increased to enhance mechanical strength, then structural integrity is improved, but fire extinguishment efficiency is reduced due to delayed agent release

Engineering Contradiction:

Improvemetal layer strengthVSAvoidfire extinguishment speed

Core Design Contradiction:

StrengthVSSpeed

Solution Approach 1:

The patent applies parameter changes by optimizing the metal layer thickness to a specific range (0.5 mm to 2 mm) and controlling the thickness of the fire extinguishing agent layer (0.1 mm to 5 mm). These parameter optimizations ensure that the metal layer provides sufficient mechanical strength while allowing the fire extinguishing agent to be released promptly when thermal runaway occurs, thus balancing structural integrity with fire extinguishment efficiency.

Inventive Principle:

Principle #35Parameter changes

3Strength

If a resin layer is added between the metal layer and fire extinguishing agent layer to improve adhesion, then bonding strength is enhanced, but response time to fire may be delayed

Engineering Contradiction:

Improvelayer adhesionVSAvoidfire response time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent applies parameter changes by precisely controlling the resin layer thickness to a narrow range (0.01 mm to 0.1 mm). This thin resin layer provides sufficient adhesion between the metal layer and fire extinguishing agent layer while minimizing the barrier to heat transfer, ensuring that the fire extinguishing agent can be released quickly when thermal runaway occurs, thus balancing bonding strength with rapid fire response.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If fire extinguishing agent layer thickness is increased to improve extinguishment capability, then fire suppression effectiveness is enhanced, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvefire extinguishment capabilityVSAvoidlaminating process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by optimizing the fire extinguishing agent layer thickness to a specific range (0.1 mm to 5 mm). This optimized thickness provides sufficient fire extinguishment capability while remaining manageable for lamination processes, thus balancing fire suppression effectiveness with manufacturing ease and cost control.

Inventive Principle:

Principle #35Parameter changes

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 increases the time for evacuation by automatically extinguishing initial fires and preventing their spread, ensuring passenger safety while maintaining mechanical strength and allowing for potential reuse of unignited batteries.

Implementation Method 1

a fire extinguishing agent layer laminated on the metal layer and including a solid fire extinguishing agent for metal fires

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 2

a fire extinguishing agent layer laminated on the metal layer and including a solid fire extinguishing agent for metal fires

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20250007087A1Self-extinguishable exterior material for battery module or battery pack

Publication Date: 2025.01.02 REPUBLIC OF KOREA (NTL FORENSIC SERVICE DIRECTOR MINIST OF PUBLIC ADMINISTRATION & SECURITY)

AI summary

An exterior material for battery module or battery pack includes a metal layer including aluminum or an aluminum alloy and a fire extinguishing agent layer laminated on the metal layer and including a solid fire extinguishing agent for metal fires.