Multilayer Battery Module Pad for Swelling and Heat Containment
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Solution Overview
Problem
Battery modules face safety issues due to thermal runaway events causing heat or flame spread and swelling of cells, leading to physical damage, and existing solutions to mitigate swelling increase the module's volume.
Innovation Solution
A pad comprising a surface pressure layer, barrier layers, and a reinforcement layer with expansion and support layers, providing heat resistance and mitigating swelling effects while maintaining a small thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a frame-retardant member or surface pressure member is inserted between adjacent battery cells to prevent swelling damage, then the swelling protection performance is improved, but the volume of the battery module increases
Solution Approach 1:
The patent employs a thin film pad structure with multiple functional layers (surface pressure layer, barrier layers, reinforcement layer) that provides swelling protection and thermal insulation without requiring bulky frame-retardant members. The flexible thin film design allows effective protection while maintaining compact battery module volume.
Solution Approach 2:
The pad comprises a composite multi-layer structure combining different materials with specific functions: surface pressure layer (silicone, polyurethane, or rubber), barrier layers (fibers or inorganic materials), and reinforcement layer (expanded graphite, silicate, or phosphorus-based flame retardants). This composite structure achieves both swelling protection and thermal resistance in a thin profile.
2Temperature
If the thickness of the pad is increased to improve heat resistance performance, then the heat resistance is improved, but the volume of the battery module increases
Solution Approach 1:
The multi-layer composite structure concentrates thermal protection functions in specific thin layers: the barrier layers (0.05-1.0 mm each) provide primary thermal resistance, while the reinforcement layer with expanded graphite or flame retardants enhances heat resistance without requiring overall pad thickening. This achieves high heat resistance performance with controlled thickness (0.55-5.5 mm).
Solution Approach 2:
The patent applies thermal protection locally where most needed - the barrier layers are positioned directly adjacent to battery cells for immediate thermal protection, while the surface pressure layer provides localized pressure distribution. This localized quality approach optimizes heat resistance without uniformly increasing pad thickness throughout.
3Reliability
If a frame-retardant member is inserted to prevent thermal runaway spread, then the safety performance is improved, but the device complexity increases
Solution Approach 1:
The thin film pad performs multiple safety functions simultaneously: the surface pressure layer provides swelling pressure distribution, the barrier layers provide thermal insulation and flame retardation, and the reinforcement layer provides structural support and additional thermal protection. This multi-functionality in a single component reduces overall device complexity compared to separate frame-retardant members and other protective components.
Solution Approach 2:
The patent merges multiple protective functions (swelling protection, thermal insulation, flame retardation, structural support) into a single integrated pad component. This consolidation simplifies the battery module structure by eliminating the need for separate frame-retardant members and multiple protective layers, reducing assembly complexity while maintaining comprehensive safety performance.
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 pad effectively suppresses heat and flame propagation, relieves pressure from swelling, and maintains a compact size, enhancing safety and efficiency of battery modules and packs.
Implementation Method 1
The reinforcement layer may include an expansion layer, and the expansion layer may be arranged in the predetermined stacking direction in at least one of between the surface pressure layer and the first barrier layer and between the surface pressure layer and the second barrier layer
Implementation Method 2
a first barrier layer and a second barrier layer respectively stacked on both surfaces of the surface pressure layer
Implementation Method 3
The expansion layer may include at least one selected from the group consisting of expanded graphite, silicate, and phosphorus-based flame retardants
Data Source
AI summary
The present disclosure relates to a pad, a battery module including the pad, and a battery pack according to embodiments of the present disclosure. The pad according to an embodiment may include a surface pressure layer having a shape of a sheet, a first barrier layer and a second barrier layer respectively stacked on both surfaces of the surface pressure layer in a predetermined stacking direction, and a reinforcement layer arranged in the predetermined stacking direction.