Battery Pack Foamable Barrier for Thermal Runaway Insulation
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Solution Overview
Problem
The safety of secondary batteries used in vehicles is a key concern due to the potential for thermal runaway events, which can compromise the safety of occupants.
Innovation Solution
Incorporating a foamable refractory material layer between the frame and the battery pack to form an insulating carbonized layer during thermal runaway, providing a barrier to high-temperature gases and flames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a secondary battery is used in a vehicle, then energy storage capacity is improved, but safety during thermal runaway events deteriorates
Solution Approach 1:
A foamable layer is introduced as an intermediary substance between the battery pack and the vehicle frame. This layer contains foamable refractory material that forms an insulating carbonized barrier during thermal runaway events, preventing direct contact between high-temperature gases/flames and the frame, thus resolving the safety issue while maintaining energy storage functionality
Solution Approach 2:
The foamable refractory material undergoes phase transition from a foamable state to a carbonized insulating layer when exposed to high temperatures during thermal runaway. This phase change creates an protective barrier that isolates the heat source from the vehicle frame, addressing the safety concern without compromising the battery's energy storage capability
2Volume of moving object
If the battery pack is positioned close to the frame, then space utilization is improved, but heat insulation performance deteriorates
Solution Approach 1:
The foamable layer is applied locally at the interface between the battery pack and the vehicle frame, specifically where thermal runaway risks are highest. This localized approach provides targeted heat insulation where needed most, maintaining close positioning for space efficiency while preventing heat transfer to critical structural components
3Object-affected harmful factors
If a foamable layer is added between the frame and battery pack, then safety during thermal runaway is improved, but device complexity increases
Solution Approach 1:
The foamable layer utilizes changes in physical parameters (temperature, volume, density) during thermal events. The material remains compact during normal operation but expands and carbonizes when exposed to heat, providing safety functionality without requiring complex active control systems or additional structural components
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
Enhances vehicle safety by containing and insulating thermal runaway events, preventing damage to the frame and improving overall safety.
Implementation Method 1
The foamable layer may be configured to form a foamed layer, which is an insulating carbonized layer, when a thermal runaway event occurs in the battery pack
Implementation Method 2
The foamable layer may be configured to form a foamed layer, which is an insulating carbonized layer, when a thermal runaway event occurs in the battery pack
Implementation Method 3
The foamable layer may be configured to form a foamed layer, which is an insulating carbonized layer, when a thermal runaway event occurs in the battery pack
Implementation Method 4
The foamable material may be configured to form a foamed layer when a thermal runaway event occurs in the battery pack
Implementation Method 5
The foamable material may be configured to form a foamed layer when a thermal runaway event occurs in the battery pack
Data Source
AI summary
A vehicle may include a frame, and a battery pack spaced apart from the frame. The battery pack may include a housing and a plurality of exhaust devices coupled to the housing. The vehicle may further include a foamable layer interposed between the frame and the battery pack. The foamable layer may contain a foamable refractory material.