Battery Pack Thermal Insulation Using Silicone Syntactic Foam
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Solution Overview
Problem
Existing secondary battery packs, particularly those with lithium-ion cells, face challenges with thermal management, leading to potential thermal excursions and propagation within the battery pack, which can result in reduced performance, safety risks, and damage due to uncontrolled heat generation.
Innovation Solution
The use of a silicone rubber syntactic foam, comprising a silicone rubber binder and hollow glass beads, for thermal insulation within the battery pack. This foam fills the open spaces within the battery module casing and covers the battery cells, providing effective thermal insulation and minimizing the propagation of thermal excursions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are closely packed to increase energy density, then productivity and space utilization improve, but thermal management deteriorates and thermal propagation risk increases
Solution Approach 1:
The patent introduces a thermal barrier material as an intermediary substance positioned between adjacent battery cells. This material acts as a mediator that blocks thermal energy transfer while allowing the cells to remain closely packed, thus resolving the contradiction between high energy density and thermal management.
Solution Approach 2:
The patent applies thermal barrier materials specifically at critical interfaces between battery cells where heat transfer is most problematic. This localized application provides targeted thermal protection without compromising the overall energy density of the battery pack.
2Reliability
If thermal insulation material is added to prevent thermal propagation, then safety improves, but device complexity and space occupation increase
Solution Approach 1:
The patent employs porous thermal barrier materials that provide effective thermal insulation while maintaining low density and minimal volume occupation. The porous structure allows the material to achieve high insulation performance without adding significant complexity or space requirements to the battery pack design.
3Object-affected harmful factors
If thermal barrier material is used to insulate battery cells, then thermal propagation is minimized, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates thermal barrier materials during the battery cell assembly process itself, rather than as a separate post-assembly step. This preliminary integration simplifies manufacturing by combining thermal protection with the existing assembly workflow, reducing overall manufacturing complexity.
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 silicone rubber syntactic foam effectively insulates battery cells from temperature extremes, preventing thermal excursions from propagating throughout the battery pack, thereby enhancing safety, reducing the risk of damage, and maintaining optimal battery performance across a wide temperature range.
Implementation Method 1
The silicone rubber syntactic foam effectively insulates battery cells from temperature extremes, preventing thermal excursions from propagating throughout the battery pack
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.