Thermoset Protective Plate for Battery Cell Heat Insulation
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Solution Overview
Problem
Existing battery modules lack adequate heat resistance and thermal insulation in members disposed on the side surfaces of battery cells.
Innovation Solution
A protective plate formed from a thermosetting resin composition, comprising phenol resin, unsaturated polyester, diallylphthalate resin, or epoxy resin, and inorganic fiber fillers, with specific flexural modulus and thermal conductivity properties, is used to enhance heat resistance and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional materials are used for protective plates on battery cell side surfaces, then manufacturing is simpler and cost is lower, but heat resistance and thermal insulation are insufficient
Solution Approach 1:
The protective plate uses a composite material consisting of thermosetting resin (phenol resin, unsaturated polyester, diallylphthalate resin, or epoxy resin) combined with inorganic fiber fillers (glass fiber, rock wool, or ceramic fiber) in specific ratios. This composite structure provides both excellent heat resistance and thermal insulation properties while maintaining manufacturability through injection molding or compression molding processes.
Solution Approach 2:
The patent specifies precise parameter ranges for the thermosetting resin composition, including thermal conductivity (20 W/m·K or less) and retention rate of flexural modulus (75% or more after high-temperature exposure). By controlling these parameters within defined ranges, the material achieves optimal heat resistance and thermal insulation performance.
2Temperature
If conventional materials are used for protective plates, then material selection is simpler, but thermal insulation performance is inadequate
Solution Approach 1:
The protective plate employs a composite material system combining thermosetting resin with specific inorganic fiber fillers (glass fiber, rock wool, or ceramic fiber) in controlled ratios. This composite structure provides superior thermal insulation performance by creating a material with both organic binding properties and inorganic insulating characteristics.
Solution Approach 2:
The patent defines specific parameter ranges for thermal conductivity (20 W/m·K or less) and retention rate of flexural modulus (75% or more after high-temperature exposure at 450°C for 3 minutes). These parameter specifications ensure optimal thermal insulation performance while maintaining structural integrity under thermal stress.
3Temperature
If high heat resistance materials are used, then temperature resistance improves, but mechanical strength at high temperature may deteriorate
Solution Approach 1:
The protective plate uses a composite material where thermosetting resin provides mechanical strength and structural integrity, while inorganic fiber fillers (glass fiber, rock wool, or ceramic fiber) provide heat resistance and dimensional stability. This synergistic combination ensures that the material maintains its flexural modulus (75% or more retention) even after exposure to high temperatures of 450°C for 3 minutes.
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 protective plate provides improved heat resistance and thermal insulation, maintaining structural integrity and reducing deformation while enhancing dielectric breakdown strength and productivity.
Implementation Method 1
the thermosetting resin composition is injection-molded under conditions of a curing temperature of 175°C and a curing time of 60 seconds
Implementation Method 2
an inorganic fiber filler, and in the cured product of the thermosetting resin composition, a thermal conductivity is 20 W/m·K or less
Implementation Method 3
the obtained test plate is heated under conditions of 180°C and 4 hours; next, the test plate is placed in a muffle furnace, is subjected to high-temperature exposure in the atmosphere at 450°C for 3 minutes
Data Source
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AI summary
According to the present invention, there is provided a protective plate for battery cells that is disposed on at least a side surface of a battery cell in a battery module including a plurality of battery cells, in which the protective plate is formed of a cured product of a thermosetting resin composition, the thermosetting resin composition includes a thermosetting resin including at least one of a phenol resin, unsaturated polyester, a diallylphthalate resin, and an epoxy resin, and an inorganic fiber filler, and in the cured product of the thermosetting resin composition, a thermal conductivity is 20 W/m ·K or less and a retention rate of flexural modulus measured at in the following high-temperature exposure test is 75% or more and 100% or less.