Battery Pack Insulation Foam for Thermal Runaway Containment
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Solution Overview
Problem
Lithium-ion battery packs face challenges with thermal management, particularly in extreme temperatures, leading to uncontrolled thermal excursions and reduced performance, which can result in battery damage and safety risks, as well as drivetrain oscillations and noise issues in electric vehicles.
Innovation Solution
A secondary battery pack utilizing a silicone rubber syntactic foam with hollow glass beads for thermal insulation and damping, which effectively minimizes temperature differences between cells, absorbs heat during thermal events, and reduces drivetrain oscillations through efficient heat dissipation and noise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional thermal management systems are used in lithium-ion battery packs, then heat dissipation is achieved, but thermal insulation is insufficient leading to uncontrolled thermal excursions and temperature propagation between cells
Solution Approach 1:
The patent applies different thermal management properties to different regions: thermal insulation material is placed between battery cells to prevent heat propagation, while thermal management systems with cooling channels are integrated into the battery pack structure for active cooling. This local differentiation allows simultaneous heat isolation and heat dissipation in appropriate locations.
Solution Approach 2:
The patent employs composite thermal management structures combining thermal insulation materials (such as aerogels, foam materials) with thermally conductive cooling components. This composite approach creates a dual-function system that both isolates heat between cells and actively removes heat from the battery pack.
2Quantity of substance
If battery cells are closely packed to increase energy density, then space utilization is improved, but thermal isolation between cells is reduced leading to faster thermal propagation
Solution Approach 1:
The patent introduces thermal insulation material specifically at the interfaces between battery cells, maintaining close packing for high energy density while creating localized thermal barriers where needed. The insulation material is positioned in the gaps and contact areas between cells to prevent thermal propagation pathways.
3Reliability
If thermal insulation material is added to prevent heat propagation, then thermal management is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent utilizes thin-film thermal insulation materials and flexible insulation layers that can be applied directly to battery cell surfaces or integrated into the pack structure. These thin insulation layers provide effective thermal barriers without adding significant thickness or structural complexity.
Solution Approach 2:
The patent integrates thermal insulation functions into existing battery pack components such as the housing, mounting structures, or cooling system components. By making existing components serve dual purposes (structural support plus thermal insulation), the overall device complexity is minimized while still achieving thermal protection.
4Object-generated harmful factors
If conventional damping materials are used to reduce drivetrain oscillations, then vibration control is achieved, but thermal management capabilities are insufficient
Solution Approach 1:
The patent employs composite materials that combine vibration damping properties with thermal management capabilities. These composite damping structures can conduct heat effectively while providing oscillation reduction, serving both thermal and mechanical functions simultaneously.
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 provides enhanced thermal management, preventing battery damage from thermal excursions, improving battery performance across a wide temperature range, and reducing drivetrain oscillations and noise in electric vehicles, thereby ensuring safer and more efficient operation.
Implementation Method 1
A secondary battery pack utilizing a silicone rubber syntactic foam with hollow glass beads for thermal insulation
Implementation Method 2
absorbs heat during thermal events
Implementation Method 3
damping, which effectively minimizes temperature differences between cells, absorbs heat during thermal events, and reduces drivetrain oscillations
Data Source
AI summary
The present invention relates to a novel secondary battery pack with improved thermal management useful for an all-electric vehicle (EV), a plug-in hybrid vehicle (PHEV), a hybrid vehicle (HEV), or battery packs used for other vehicles batteries, and more particularly, to the use of a specific material for thermally insulating a secondary battery pack and further minimizing the propagation of thermal runaway within a battery pack.